Fire-rated joint system

ABSTRACT

A fire-rated angle piece and wall assemblies or other assemblies that incorporate the fire-rated angle piece, in which the angle piece can include an intumescent or other fire-resistant material strip. The angle can be attached adjacent to a corner of a framing member, such as metal tracks, headers, header tracks, sill plates, bottom tracks, metal studs, wood studs or wall partitions, and placed between the framing member and a wall board member at a perimeter of a wall assembly to create a fire block arrangement. A fire spray material can be applied over a portion of the angle piece.

RELATED APPLICATIONS

Related applications are listed in an Application Data Sheet (ADS) filedwith this application. All applications listed in the ADS are herebyincorporated by reference herein in their entireties.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention generally relates to fire-rated buildingstructures. In particular, the present invention relates to fire-ratedjoint systems, wall assemblies, and other building structures thatincorporate the fire-rated joint systems.

Description of the Related Art

Fire-rated construction components and assemblies are commonly used inthe construction industry. These components and assemblies are aimed atpreventing fire, heat, and smoke from leaving one room or other portionof a building and entering another room or portion of a building. Thefire, heat or smoke usually moves between rooms through vents, joints inwalls, or other gaps or openings. The fire-rated components oftenincorporate fire-retardant materials which substantially block the pathof the fire, heat or smoke for at least some period of time. Intumescentmaterials work well for this purpose, because they swell and char whenexposed to flames helping to create a barrier to the fire, heat, and/orsmoke.

One particular wall joint with a high potential for allowing fire, heator smoke to pass from one room to another is the joint between the topof a wall and the ceiling, which can be referred to as a head-of-walljoint. In modern multi-story or multi-level buildings, the head-of-walljoint is often a dynamic joint in which relative movement between theceiling and the wall is permitted. This relative movement is configuredto accommodate deflection in the building due to loading of the ceilingor seismic forces. The conventional method for creating a fire-ratedhead-of-wall joint is to stuff a fire-resistant mineral wool materialinto the head-of-wall joint and then spray an elastomeric material overthe joint to retain the mineral wool in place. This conventionalconstruction of a fire-rated head-of-wall joint is time-consuming,expensive and has other disadvantages that are described herein.

A wall assembly commonly used in the construction industry includes aheader track, bottom track, a plurality of wall studs and a plurality ofwall board members, possibly among other components. A typical headertrack resembles a generally U-shaped (or some other similarly shaped)elongated channel capable of receiving or covering the ends of wallstuds and holding the wall studs in place. The header track also permitsthe wall assembly to be coupled to an upper horizontal supportstructure, such as a ceiling or floor of a higher level floor of amulti-level building.

Header tracks generally have a web and at least one flange extendingfrom the web. Typically, the header track includes a pair of flanges,which extend in the same direction from opposing edges of the web. Theheader track can be slotted header track, which includes a plurality ofslots spaced along the length of the track and extending in a verticaldirection. When the wall studs are placed into the slotted track, eachof the plurality of slots accommodates a fastener used to connect thewall stud to the slotted track. The slots allow the wall studs to movegenerally orthogonally relative to the track. In those areas of theworld where earthquakes are common, movement of the wall studs isimportant. If the wall studs are rigidly attached to the slotted trackand not allowed to move freely in at least one direction, the stabilityof the wall and the building might be compromised. With the plurality ofslots, the wall studs are free to move. Even in locations in whichearthquakes are not common, movement between the studs and the headertrack can be desirable to accommodate movement of the building structuredue to other loads, such as stationary or moving overhead loads, asdescribed above.

Recently, improved methods of providing a fire-rated head-of-wall jointhave been developed. One example of a fire-rated wall constructioncomponent is a head-of-wall fire block device sold by the Assignee ofthe present application under the trademark FireStik®. The FireStik®fire block product incorporates a metal profile with a layer ofintumescent material on its inner surface. The metal profile of theFireStik® fire block product is independently and rigidly attached to astructure, such as the bottom of a floor or ceiling, at a positionadjacent to the gap between the wallboard (e.g., drywall) and theceiling on the opposite side (i.e., outside) of the wallboard relativeto the studs and header track. The intumescent material, which isadhered to the inner surface of the metal profile, faces the wallboard,stud and header track. The space created in between the wallboard andceiling, and the space between the stud and header track, allows forindependent vertical movement of the stud in the header track when nofire is present.

When temperatures rise, the intumescent material on the FireStik® fireblock product expands rapidly and chars. This expansion creates abarrier which fills the head-of-wall gap and inhibits or at leastsubstantially prevents fire, heat and smoke from moving through thehead-of-wall joint and entering an adjacent room for at least someperiod of time.

Still another example of an improved construction component for creatinga fire-rated head-of-wall joint is a header track with integratedintumescent material strips sold by the Assignee of the presentapplication under the trademark FAS Track®. In contrast to the FireStik®fire block product, the FAS Track® header track product incorporates theintumescent material directly on the header track so that the fire blockmaterial is installed during the framing process. Both the FireStik® andthe FAS Track® fire block products are typically installed by theframing crew. The integration of the intumescent material into the FASTrack® header track product can eliminate the need to install anadditional fire block product after the wall board has been installed,which is typically done by a different crew than the framing crew.

SUMMARY OF THE INVENTION

Although the FireStik® and the FAS Track® products represent animprovement over the conventional method of stuffing mineral woolmaterial into the head-of-wall joint and applying the elastomeric spraymaterial over the mineral wool, there still exists room for improvedproducts and methods for efficiently and cost-effectively creatingfire-rated wall joints. Certain embodiments of the present inventioninvolve a fire-rated angle piece that incorporates a fire-resistant orintumescent material on at least one surface of the angle piece. Theangle piece is separate from the header track, but is configured to beinstalled prior to the installation of the wall board and, preferably,during the framing process. Advantageously, the present angle piece canbe installed along with the installation of the header track or can beinstalled after the installation of the header track. Such anarrangement avoids the need to have the framers return after theinstallation of the wall board. In addition, the angle piece can bestacked and shipped without damaging the intumescent material moreeasily than a header track that incorporates the intumescent material.

An embodiment involves a fire-rated assembly for a linear wall gap,which includes a track that has a web, a first flange and a secondflange. The web is substantially planar and has a first side edge and asecond side edge. The first flange and the second flange extend in thesame direction from the first and second side edges, respectively. Eachof the first and second flanges is substantially planar such that thetrack defines a substantially U-shaped cross section. An angle has afirst flange and a second flange, wherein each of the first flange andthe second flange is substantially planar such that the angle defines asubstantially L-shaped cross section. Each of the first and secondflanges has a free end opposite a corner of the angle. In someembodiments, a heat-expandable intumescent strip is attached to theangle and extends lengthwise along an outer surface of the secondflange. The intumescent strip comprises a portion that extends past anouter surface of the first flange of the angle. The first flange of theangle is positioned between the web of the track and an overheadstructure with the second flange of the angle being positioned adjacentone of the first or second flanges of the track with at least a portionof the second flange contacting the one of the first or second flangesof the track.

In other embodiments, a heat-expandable intumescent strip is attached tothe angle and extends lengthwise along an interior surface of the secondflange. In use, the first flange of the angle is positioned between theweb of the track and an overhead structure with the second flange of theangle being positioned adjacent one of the first or second flanges ofthe track such that the intumescent strip is between the second flangeand the one of the first or second flanges of the track.

In some arrangements, an upper edge of the intumescent strip is spacedbelow an upper end of the second leg thereby defining an upper portionof the second leg that is not covered by the intumescent strip. A loweredge of the intumescent strip can be spaced above a lower end of thesecond leg thereby defining a lower portion of the second leg that isnot covered by the intumescent strip. A height of the intumescent stripcan be about twice a height of the upper portion of the second leg. Aheight of the lower portion of the second leg can be about twice theheight of the intumescent strip.

In some arrangements, a height of the intumescent strip is equal to orless than about one-half of a height of the second leg. In otherarrangements, the height of the intumescent strip is equal to or lessthan about one-third of a height of the second leg. The second flange ofthe angle can be approximately the same height as the one of the firstand second flange of the track. A plurality of slots can be included onthe first and second flanges of the track, which extend in a directionperpendicular to a length of the first track and the second flange ofthe angle can cover an entirety of the slots.

In some arrangements, the wall assembly includes a plurality of studsand a wall board, wherein an upper end of each of the studs is receivedwithin and secured to the track and the wall board is secured to theplurality of studs, and wherein the second flange of the angle ispositioned between the wall board and the one of the first and secondflanges of the track. The wall assembly can define a maximum distance ofrelative movement between the track and the plurality and studs or thewall board, wherein a height of the intumescent strip is about one-halfor less than the maximum distance. The assembly can include a layer ofan elastomeric fire spray material applied to the overhead structure andthe angle. The layer of fire spray material preferably is not applied tothe wall board.

In some arrangements, an angle is defined between the first flange andthe second flange of the angle that is less than 90 degrees such that agap is created between an upper end of the second flange of the angleand an upper end of the one of the first and second flanges of thetrack. The angle can be approximately 87 degrees.

The assembly can include a second intumescent strip that extends alongand is attached to a portion of the first flange of the angle such thanthe portion contacts the overhead structure when the fire-rated assemblyis assembled to the overhead structure. The track can be a footer orheader track. The track can be a stud framing member made from wood ormetal.

An embodiment involves a fire-rated wall joint product, which includesan elongated, generally L-shaped angle piece having a first flange and asecond flange oriented at an angle relative to the first flange. Thefirst flange and the second flange each have a free edge and areconnected to one another along an edge that is opposite the free edgesthereby defining a corner. The first flange and second flange are formedfrom a single piece of material. An intumescent material strip isapplied to an interior surface of the second flange and a height of theintumescent material strip is equal to or less than about one-half aheight of the second flange.

In some arrangements, the height of the intumescent material strip isequal to or less than about one-third of the height of the secondflange. The height of the intumescent material strip can be aboutone-seventh of the height of the second flange. The intumescent materialstrip can be spaced from an upper end of the second flange.

An embodiment involves a method of assembling a fire-rated wall joint,including securing a header track to a ceiling, positioning a horizontalleg of an elongated, generally L-shaped fire-rated angle piece betweenthe header track and the ceiling such that at least a portion of anintumescent material strip located on a vertical leg of the angle piecefaces toward the header track, positioning upper ends of a plurality ofstuds into the header track, and securing at least one wall board memberto the plurality of studs such that the vertical leg of the angle pieceis positioned between the at least one wall board member and the headertrack.

Another embodiment involves a method of assembling a fire-rated walljoint, including securing a header track to a ceiling, positioning ahorizontal leg of an elongated, generally L-shaped fire-rated anglepiece between the header track and the ceiling such that at least aportion of an intumescent material strip located on a vertical leg ofthe angle piece faces away from the header track, positioning upper endsof a plurality of studs into the header track, and securing at least onewall board member to the plurality of studs such that the vertical legof the angle piece is positioned between the at least one wall boardmember and the header track.

In some arrangements, the positioning of the horizontal leg between theheader track and the ceiling is done after the securing of the headertrack to the ceiling. The method can also include applying a layer of anelastomeric fire spray to the ceiling and the angle piece and not to theat least one wall board member.

In some arrangements, a fire-rated wall joint product includes anelongated, generally L-shaped angle piece comprising a first flange anda second flange oriented at an angle relative to the first flange. Thefirst flange and the second flange each have a free edge and areconnected to one another along an edge that is opposite the free edgesthereby defining a corner. The first flange and second flange can beformed from a single piece of material. The wall joint product can alsoinclude a first intumescent material strip applied to an interiorsurface of the first flange, wherein a height of the intumescentmaterial strip is equal to or less than about one-half a height of thefirst flange. The wall joint product can further include a secondintumescent material strip applied to an interior surface of the secondflange, wherein a height of the intumescent material strip is equal toor less than about one-half a height of the second flange.

In some arrangements, the height of the first intumescent material stripis equal to or less than about one-third of the height of the firstflange. The height of the second intumescent material strip can be equalto or less than about one-third of the height of the second flange. Inother arrangements, the height of the first intumescent material stripis about one-seventh of the height of the first flange. The height ofthe second intumescent material strip can be about one-seventh of theheight of the second flange. In some arrangements, the first intumescentmaterial strip is spaced from the corner. In other arrangements, thesecond intumescent material strip can be spaced from an upper end of thesecond flange.

An embodiment involves a method of assembling a fire-rated wall jointproduct, including securing a header track to a ceiling; positioningupper ends of a plurality of studs into the header track; positioning anelongated, generally L-shaped angle piece between the header track andthe ceiling, the L-shaped angle piece comprising a first flange, asecond flange oriented at an angle relative to the first flange, and anintumescent material strip applied to an exterior surface of the secondflange, the first flange and the second flange each having a free edgeand being connected to one another along an edge that is opposite thefree edges thereby defining a corner, the first flange and second flangeformed from a single piece of material; and securing at least one wallboard member to the plurality of studs such that the second flange ispositioned between the at least one wall board member and the headertrack.

Another embodiment involves a method of assembling a fire-rated walljoint product, including securing a header track to a ceiling;positioning upper ends of a plurality of studs into the header track;positioning an elongated, generally L-shaped angle piece between theheader track and the ceiling, the L-shaped angle piece comprising afirst flange, a second flange oriented at an angle relative to the firstflange, a flap, and an intumescent material strip applied to an exteriorsurface of the second flange, the first flange and the flap each havinga free edge, the first flange and the second flange being connected toone another along an edge thereby defining a first corner and the secondfirst flange and the flap being connected to one another along an edgethereby defining a second corner, the first flange and the second flangeeach being planar, the first and second flange and the flap being formedfrom a single piece of material; and securing at least one wall boardmember to the plurality of studs such that the second flange ispositioned between the at least one wall board member and the headertrack.

In some arrangements, a fire-rated assembly for a linear wall gapincludes a track that has a web, a first flange and a second flange,wherein the web is substantially planar and has a first side edge and asecond side edge, the first flange and the second flange extend in thesame direction from the first and second side edges, respectively,wherein each of the first and second flanges is substantially planarsuch that the track defines a substantially U-shaped cross section; anangle piece comprising a first flange, a second flange oriented at afirst angle relative to the first flange, a flap oriented at a secondangle relative to the first flange, and an intumescent material stripapplied to an exterior surface of the second flange, the second flangeand the flap each having a free edge, the first flange and the secondflange being connected to one another along an edge thereby defining afirst corner and the first flange and the flap being connected to oneanother along an edge thereby defining a second corner, the first flangeand the second flange each being planar, the first and second flangesand the flap being formed from a single piece of material; aheat-expandable intumescent strip attached to the angle and extendinglengthwise along an interior surface of the second flange; wherein, inuse, the first flange of the angle is positioned adjacent to an overheadstructure with the second flange of the angle being positioned adjacentone of the first or second flanges of the track such that theintumescent strip is between the second flange and a wall board.

In other arrangements, a fire-rated wall joint product includes anelongated, generally L-shaped angle piece comprising a first flange, asecond flange oriented at a first angle relative to the first flange,and a flap oriented at a second angle to the first flange, the secondflange and the flap each having a free edge, the first flange and thesecond flange connected to each other along an edge thereby defining afirst corner, the first flange and the flap connected to one anotheralong an edge thereby defining a second corner, the first flange and theflap being planar, the first and second flanges and the flap beingformed from a single piece of material; and an intumescent materialstrip applied to an exterior surface of the first flange, wherein aheight of the intumescent material strip is equal to or less than aboutone-half a width of the first flange.

In some arrangements, the fire-rated joint product further includes asecond intumescent material applied to an exterior surface of the secondflange. In some arrangements, the second flange further comprises akickout portion such that a lower portion of the second flange isparallel to the upper portion of the second flange. In somearrangements, the flap further comprises a second intumescent stripapplied to an interior surface of the flap. In some arrangements, theflap further comprises a first section and a second section oriented atan angle relative to the first second, the first section and the secondsection being connected to one another along an edge defining a corner,the second portion substantially parallel to the first flange. In somearrangements, the intumescent material strip wraps the first cornerbetween the first flange and the second flange.

In another arrangement, a fire-rated wall joint product includes anelongated piece comprising a strap having a free edge and a hem havingan outwardly curved portion, the strap and the hem being formed from asingle piece of material; and an intumescent material strip applied toan exterior surface of the strap and extending beyond the free edge ofthe strap, wherein a length of the intumescent material strip is equalto or less than about one-half a height of the strap.

In some arrangements, the strap of a fire-rated joint product furtherincludes a kickout portion such that a lower portion of the strap isparallel to the upper portion of the strap. In some arrangements, thestrap has a two-ply section having a first layer and a second layer suchthat the free edge of the strap is adjacent the kickout portion of thestrap, the two-ply section forming a gap between the first layer and thesecond layer. In some arrangements, an intumescent material is appliedwithin the gap.

In yet another arrangement, a fire-rated wall joint product includes anelongated piece comprising a strap have a free edge and a S-curveattachment portion extending from an end of the strap opposite the freeedge, the strap having a kickout portion such that a lower portion ofthe strap is parallel to the upper portion of the strap, the attachmentportion forming an angle with the strap, the strap and the attachmentportion being formed from a single piece of material; and an intumescentmaterial strip applied to an exterior surface of the strap such that theintumescent material extends above a junction between the attachmentportion and the strap, wherein a length of the intumescent materialstrip is equal to or less than about one-half a height of the strap.

In another embodiment, a fire-blocking wall assembly includes a firstwall partition comprising a first surface; a second wall partitioncomprising a second surface; wherein the first wall partition and thesecond wall partition move laterally and vertically with respect to eachother; a fire-blocking drift joint comprising a body having a first end,a second end, and a compressible portion between the first end and thesecond end, the compressible portion having a first leg and a second legsuch that the first and second legs form an angle, the first end havinga first flange, the second end having a second flange, each of the firstend and the second end having a free end opposite the compressibleportion, the drift joint further comprising a fire-retardant materialapplied to an outer surface of the second flange; wherein thefire-blocking drift joint is installed between the first wall partitionand the second wall partition; wherein the first flange attaches to thesecond surface of the second wall partition and the second flangeengages the first surface of the first wall partition.

In some arrangements, the body comprises a single piece of steel. Insome arrangements, the body comprises two pieces of steel mechanicallyfastened together. In some arrangements, the compressible sectioncomprises a first and second layer of steel. In some arrangements, aspace created between the first and second layer of steel is at leastpartially filled with a fire-retardant material. In some arrangements,the compressible section has a U-shaped or a V-shaped profile. In somearrangements, each of the first flange and the second flange issubstantially planar such that the body defines a substantially U-shapedcross section with the first and second ends substantially parallel. Insome arrangements, each of the first flange and the second flange isplanar such that the body defines a cross section with the first andsecond ends at an angle to each other. In some arrangements, thecompressible section is in a compressed state when inserted into thefire-seal partition interface. In some arrangements, the fire-blockingdrift joint maintains a fire-seal partition across the fire-sealpartition interface while allowing the first vertical wall partition andthe second vertical wall partition to move independently relative toeach other in both lateral and vertical directions.

In another arrangement, a fire-blocking expansion joint assemblyincludes a horizontal ceiling element comprising a first attachmentsurface; a horizontal wall element comprising a second attachmentsurface; an interface between the horizontal ceiling element and thehorizontal wall element; a fire-blocking expansion joint comprising abody having a first end, a second end, and a compressible portionbetween the first end and the second end, the compressible portionhaving a first leg and a second leg such that the first and second legscome together to form an angle that is V-shaped or U-shaped, each of thefirst end and the second end having a free end opposite the compressibleportion, the first end having a first flange, the second end having asecond flange; wherein the first flange attaches to the first attachmentsurface of the horizontal ceiling element and the second flange attachesto the second attachment surface of the horizontal wall element suchthat the fire-blocking expansion joint is installed within theinterface.

In some arrangements, the body comprises a single piece of steel. Insome arrangements, the body comprises two pieces of steel. In somearrangements, the compressible section comprises a first and secondlayer forming an open space between the first and second layers. In somearrangements, the space created between the first and second layer ofsteel is filled with a fire-retardant material. In some arrangements,the compressible section has a U-shaped or a V-shaped profile. In somearrangements, each of the first flange and the second flange issubstantially planar such that the body defines a substantially U-shapedcross section with the first and second ends substantially parallel. Insome arrangements, each of the first flange and the second flange isplanar such that the body defines a cross section with the first andsecond ends forming an angle. In some arrangements, the compressiblesection is in a compressed state when inserted into the interface. Insome arrangements, the fire-blocking expansion joint maintains afire-seal partition across the interface while allowing the horizontalceiling element and the horizontal wall element to move independentlyrelative to each other.

In another embodiment, a fire-rated assembly for a linear wall gap,includes a track, an angle piece and a heat-expandable intumescentstrip. The track that has a web, a first flange and a second flange,wherein the web is substantially planar and has a first side edge and asecond side edge, the first flange and the second flange extend in thesame direction from the first and second side edges, respectively,wherein each of the first and second flanges is substantially planarsuch that the track defines a substantially U-shaped cross section. Theangle piece has a first flange, a second flange oriented at a firstangle relative to the first flange, the first flange and the secondflange being connected to one another along an edge thereby defining acorner, the first and second flanges being formed from a non-metalmaterial. The heat-expandable intumescent strip attached to one of thefirst and second flanges of the angle piece, the heat-expandableintumescent strip having an activation temperature that is lower than amelting temperature of the non-metal material. In use, the first flangeof the angle is positioned adjacent to an overhead structure with thesecond flange of the angle being positioned adjacent one of the first orsecond flanges of the track. The angle piece is configured to deform andcontain expanding intumescent material of the heat-expandableintumescent strip when the angle piece and the heat-expandableintumescent strip are exposed to temperatures greater than theactivation temperature.

In some arrangements, the non-metal material is comprised of polyvinylchloride (PVC).

In another embodiment, a fire-rated wall joint product includes an anglepiece and a heat-expandable intumescent strip. The angle piece includesa first flange, a second flange oriented at a first angle relative tothe first flange, the first flange and the second flange being connectedto one another along an edge thereby defining a corner, the first andsecond flanges being formed from a non-metal material. Theheat-expandable intumescent strip is attached to one of the first andsecond flanges, the heat-expandable intumescent strip having anactivation temperature that is lower than a melting temperature of thenon-metal material. The angle piece is configured to deform and containexpanding intumescent material of the heat-expandable intumescent stripwhen the angle piece and the heat-expandable intumescent strip areexposed to temperatures greater than the activation temperature.

In some arrangements, the non-metal material is comprised of polyvinylchloride (PVC).

In another embodiment, a fire-rated wall joint product includes a bodyportion and a heat-expandable intumescent strip. The body portionincludes a first end and a second end, the body portion being formedfrom a non-metal material. The heat-expandable intumescent stripattached to the body portion between the first and second ends, theheat-expandable intumescent strip having an activation temperature thatis lower than a melting temperature of the non-metal material. Thenon-metal material is configured to deform and contain expandingintumescent material of the heat-expandable intumescent strip when thebody portion and heat-expandable intumescent strip are exposed totemperatures greater than the activation temperature.

In some arrangements, the non-metal material is comprised of polyvinylchloride (PVC).

In another embodiment, a fire-rated assembly for a linear wall gapincludes a track, an angle piece and a gasket. The track that has a web,a first flange and a second flange, wherein the web is substantiallyplanar and has a first side edge and a second side edge, the firstflange and the second flange extend in the same direction from the firstand second side edges, respectively, wherein each of the first andsecond flanges is substantially planar such that the track defines asubstantially U-shaped cross section. The angle piece comprising a firstflange, a second flange oriented at a first angle relative to the firstflange, the first flange and the second flange being connected to oneanother along an edge thereby defining a corner. The gasket is attachedto the angle piece, and the gasket comprises a compressible material. Inuse, the first flange of the angle is positioned adjacent to an overheadstructure such that the gasket contacts the overhead structure to form aseal between the first flange and the overhead structure.

In some arrangements, the gasket is attached to the first flange of theangle.

In some arrangements, a first end of the gasket is attached to the firstflange and a second end of the gasket is attached to the second flangesuch that the gasket is positioned over the corner of the angle piece.

In some arrangements, the fire-rated assembly further comprises aheat-expandable intumescent strip attached to one of the first andsecond flanges of the angle piece.

In another embodiment, a fire-rated wall joint product includes an anglepiece and a gasket. The angle piece includes a first flange, a secondflange oriented at a first angle relative to the first flange, the firstflange and the second flange being connected to one another along anedge thereby defining a corner. The gasket is attached to the anglepiece, the gasket comprising a compressible material.

In some arrangements, the gasket is attached to the first flange of theangle.

In some arrangements, a first end of the gasket is attached to the firstflange and a second end of the gasket is attached to the second flangesuch that the gasket is positioned over the corner of the angle piece.

BRIEF DESCRIPTION OF THE DRAWINGS

Certain features, aspects and advantages of the various devices, systemsand methods presented herein are described with reference to drawings ofcertain embodiments, which are intended to illustrate, but not to limit,such devices, systems, and methods. It is to be understood that thedrawings are for the purpose of illustrating concepts of the embodimentsdiscussed herein and may not be to scale. For example, certain gaps orspaces between components illustrated herein may be exaggerated toassist in the understanding of the embodiments. Dimensions, if providedin the specification, are merely for the purpose of example in thecontext of the specific arrangements shown and are not intended to limitthe disclosure. The drawings contain twenty-eight (28) figures.

FIG. 1 is a perspective view of a fire-rated angle piece, whichincorporates a fire-resistant or intumescent material strip.

FIG. 2 is a cross-sectional view of the fire-rated angle piece of FIG.1.

FIG. 3 is a cross-sectional view of a head-of-wall joint incorporatingthe fire-rated angle piece of FIG. 1.

FIG. 4 is a cross-sectional view of an alternative fire-rated anglepiece that includes a retention feature on an upper wall portion of theangle piece.

FIG. 5 is a cross-sectional view of another alternative fire-rated anglepiece that includes another retention feature, in the form of a hem, onthe upper wall portion of the angle piece.

FIG. 6 is a perspective view of another fire-rated angle piece thatincorporates notches or slots in the upper wall portion to allow bendingof the angle piece or accommodate fasteners used to secure the headertrack to the ceiling.

FIG. 7 is a cross-sectional view of another fire-rated angle piece thatincludes a recess defined in the upper wall portion to accommodate theintumescent material.

FIG. 8 is a cross-sectional view of another fire-rated angle piece thatincludes an alternative configuration of a free end of a side wallportion of the angle piece.

FIG. 9 is a cross-sectional view of another fire-rated angle piece thatincludes yet another alternative configuration of the free end of theside wall portion.

FIG. 10 is a cross-sectional view of a head-of-wall assemblyincorporating another embodiment of the fire-rated angle piece. In FIG.10, the head-of-wall assembly is shown in a closed or upward position.

FIG. 11 is a cross-sectional view of the head-of-wall assembly of FIG.10 in an open or downward position.

FIG. 12 is a cross-sectional view of a head-of-wall assembly attached toa fluted pan deck ceiling arrangement and including a layer of sprayedelastomeric material.

FIG. 13 is an elevation view of the head-of-wall assembly of FIG. 12.

FIG. 14 is a cross-sectional view of an alternative fire-rated anglepiece including a hem at the free end of the upper wall portion and ahem at the free end of the side wall portion.

FIG. 15 is a top view of the fire-rated angle piece of FIG. 6.

FIG. 16 is a top view of the fire-rated angle piece of FIG. 15 in a bentconfiguration.

FIG. 17 is a perspective view of an alternative fire-rated angle piecein which the fire-retardant or intumescent material strip is positionedon the inside surface of the angle.

FIG. 18 is a cross-sectional view of the angle piece of FIG. 17.

FIG. 19 is a cross-sectional view of a head-of-wall assemblyincorporating the angle piece of FIG. 17.

FIG. 20 is an elevation view of the head-of-wall assembly of FIG. 19,with several portions broken away to reveal underlying portions.

FIG. 21 is a cross-sectional partial representation of a head-of-wallassembly similar to that of FIGS. 19 and 20 in a closed position of thehead-of-wall gap.

FIG. 22 is a cross-sectional partial representation of the head-of-wallassembly of FIG. 21 in an open position of the head-of-wall gap.

FIG. 23 is a cross-sectional partial representation of a head-of-wallassembly similar to that of FIGS. 19 and 20 prior to any significantexpansion of the intumescent material.

FIG. 24 is cross-sectional partial representation of the head-of-wallassembly of FIG. 23 after expansion of the intumescent material.

FIG. 25 is a cross-sectional view of an alternative angle piece that issimilar to the angle piece of FIGS. 17 and 18.

FIG. 26 is a cross-sectional view of another alternative angle piecethat is similar to the angle piece of FIGS. 17 and 18.

FIG. 27 is a cross-sectional view of yet another alternative angle piecethat is similar to the angle piece of FIGS. 17 and 18.

FIG. 28 is a cross-sectional view of a head-of-wall assemblyincorporating an alternative angle piece that utilizes otherfire-retardant materials in the place of an intumescent material stripsecured directly to the angle piece.

FIG. 29 is a cross-sectional view of yet another alternative angle piecethat is similar to the angle piece of FIGS. 17 and 18.

FIG. 30 is a cross-sectional view of a head-of-wall assemblyincorporating an alternative angle piece that utilizes two strips of anintumescent material strip secured directly to the angle piece.

FIG. 31 is a top view of a fire-blocking drift joint assembly installedbetween a wall and a window mullion having certain features aspects andadvantages of the present invention.

FIG. 32 is a profile view of an fire-blocking drift joint.

FIG. 33 is a profile view of a single-ply fire-blocking drift joint withattachment flange and non-attachment flange oriented 90° from eachother.

FIG. 34 is a profile view of a double-ply fire-blocking drift jointwithout a non-attachment flange.

FIG. 35 is a profile view of a double-ply fire-blocking drift joint withan intumescent strip and fire retardant material attached to thecompressible section.

FIG. 36 is a profile view of an fire-block expansion joint having twoattachment flanges.

FIG. 37 is a profile view of a double-ply fire-block expansion jointhaving two attachment flanges.

FIG. 38 is an side header block assembly view of a fire-block expansionjoint installed between a CMU concrete block wall and an I-beam sprayedwith fireproofing material.

FIG. 39 is a cross-sectional view of a fire-rated angle piece, whichincorporates a fire-resistant or intumescent strip.

FIG. 40 is a cross-sectional view of another embodiment of a fire-ratedangle piece, which incorporates a fire-resistant or intumescent strip.

FIG. 41 is a cross-sectional view of a head-of-wall assemblyincorporating another embodiment of the fire-rated angle piece.

FIG. 42 is a cross-sectional view of a head-of-wall assemblyincorporating another embodiment of the fire-rated angle piece. FIG. 42illustrates the angle piece as part of an open joint (left side) and aclosed joint (right side).

FIG. 43 is a cross-sectional view of another embodiment of a fire-ratedangle piece.

FIGS. 44A-C are cross-sectional views of three additional embodiments ofa fire-rated angle piece with the intumescent material positioned ondifferent locations of the fire-rated angle piece.

FIGS. 45A and B are cross-sectional views of other embodiments of afire-rated angle piece.

FIG. 46 is a cross-sectional view of another embodiment of a fire-ratedangle piece.

FIG. 47 is a partial cross-sectional view of another head-of-wallassembly incorporating the fire-rated angle piece of FIG. 46.

FIG. 48 is a front view of another embodiment of a fire-rated anglepiece having a plurality of cuts or slits in the steel profile along thelonger leg to create a plurality of bendable tabs.

FIG. 49 is a side view of the fire-rated angle piece of FIG. 48.

FIG. 50 is a cross-sectional view of a head-of-wall assemblyincorporating the fire-rated angle piece of FIGS. 48 and 49 illustratingthe tabs bent inward to hold vertical studs in place prior to drywallattachment.

FIG. 51 is a front elevation view of the head-of-wall assembly of FIG.50.

FIG. 52A is a cross-sectional partial representation of a head-of-wallassembly incorporating a non-metal angle piece.

FIG. 52B is a cross-sectional partial representation of the head-of-wallassembly of FIG. 52A after applying heat to the non-metal angle piece.

FIG. 53 is a cross-sectional view of an angle piece fitted with a gasketpositioned over a corner of the angle piece.

FIG. 54 is a cross-sectional partial representation of a head-of-wallassembly incorporating the angle piece of FIG. 53.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Several preferred embodiments of the fire-rated angle pieces andfire-rated joint systems are described herein, typically in the contextof a wall assembly and, in particular, a head-of-wall assembly. However,the fire-rated angle pieces and fire-rated joint systems can also beused in other applications, such as at the bottom or sides of a wall ora joint in an intermediate location of a wall. The fire-rated anglepieces and fire-rated joint systems can also be used in non-wallapplications. In view of the head-of-wall assembly being but one of themultiple applications for the fire-rated angle pieces and fire-ratedjoint systems, the use of relative or directional terminology, or othersuch descriptions, is for convenience in describing the particularembodiments, arrangements or orientations shown. Therefore, such termsare not intended to be limiting, unless specifically designated as such.

FIGS. 1-3 illustrate an embodiment of a fire-rated profile or anglepiece 20, which is also referred to herein simply as an angle 20, alone(FIGS. 1 and 2) and incorporated into a head-of-wall assembly (FIG. 3).The angle 20 preferably is formed from a light gauge steel material byany suitable process, such as roll forming, for example. Preferably, theangle 20 is an elongated member having a consistent or substantiallyconsistent cross-sectional shape throughout its length. One or morepreferred embodiments of the angle 20 are generally or substantiallyL-shaped in cross-section. In one embodiment, the angle 20 may bebetween about 5 feet and 25 feet in length. The angle 20 can be betweenabout 10 and 20 feet in length. Preferably, the angle 20 is about 10-12feet in length to facilitate shipping and storage. Desirably, the angle20 is sufficiently long to allow installation along a wall with arelatively small number of pieces. However, the length of the angle 20should be short enough that shipping and material handling is relativelyconvenient. Accordingly, the above-recited lengths are presentlypreferred. However, other lengths may also be used in other situations.

Preferably, the angle 20 includes a top or upper wall portion or top orupper leg or flange 22. The upper wall portion 22 is also referred toherein as a horizontal leg because it is typically oriented in ahorizontal or substantially horizontal plane when installed in ahead-of-wall assembly, as described herein. The angle 20 also includes aside wall portion 24, which is also referred to herein as a vertical legor flange because it is typically oriented in a vertical orsubstantially vertical plane when the angle 20 is installed in ahead-of-wall assembly. The illustrated vertical leg 24 is unitarilyformed with the horizontal leg 22. That is, the horizontal leg 22 andthe vertical leg 24 are constructed from a single piece of material. Asdescribed above, typically, the single piece of material is a flat pieceof light gauge steel, which is then deformed into the shape of the angle20, such as through a roll-forming, bending (such as on a press brake)or other suitable process. Preferably, both the horizontal leg 22 andthe vertical leg 24 are substantially planar and define an angletherebetween of about 90 degrees or, in some arrangements, slightly lessthan 90 degrees. For example, the legs 22 and 24 may define an angle ofbetween about 80 degrees and about 90 degrees, between about 85 degreesand 90 degrees or about 87 degrees. This can assist in providing a gapat the upper end of the vertical leg 24 to accommodate a fastener head,as is described in greater detail below.

In one embodiment of the light gauge steel angle 20, the horizontal leg22 can define a width 26 (i.e., horizontal cross-sectional dimension) ofabout ¾ inch or less, 1 inch or less, or 1½ inches or less. Preferably,the horizontal leg 22 is about 1½ inches wide. The vertical leg 24 candefine a width or height 28 (i.e., vertical cross-sectional dimension)between about ½ inch and about 3 inches or more depending on amount offire and smoke protection desired and/or based on deflectionrequirements. The dimensions of the width of the horizontal leg 22preferably are selected such that two angles 20 can be employed in ahead-of-wall assembly (illustrated in FIG. 3) with one angle 20 on eachside of the wall. Preferably, the width of the horizontal leg 22 isselected such that the legs 22 of the two angles 20 do not overlap oneanother when assembled into the head-of-wall assembly. Accordingly, ifthe angle 20 is configured for use with a wall assembly that is widerthan standard width, the width of the horizontal leg 22 can be increasedto, for example, about 1½ inches to about 3 inches, or more. The widthor height of the vertical leg 24 is selected such that the leg 24 fillsthe entire head-of-wall gap, or gap between the ceiling and upper endsurfaces of the wall board, in an open-most position of the head-of-walljoint (assuming a dynamic joint). Alternatively, the width or height ofthe vertical leg 24 is selected to cover a substantial portion, such as⅓ to ½ or more, of the corresponding leg of the header track. Thus, theactual width or height of the vertical leg 24 can vary from theexemplary widths or heights described herein.

Preferably, a fire retardant material or a fire retardant materialstrip, such as an intumescent tape or intumescent strip 30, isadhesively (or otherwise) applied to the full length of the fire-ratedangle 20. In a preferred arrangement, the intumescent tape 30 wraps overthe corner 32 of the angle 20 (intersection between the horizontal leg22 and the vertical leg 24) and is positioned on each of the horizontalleg 22 and vertical leg 24. Preferably, the intumescent tape 30 extendsonly partially across the horizontal leg 22 and extends substantially orentirely across the vertical leg 24. Preferably, the intumescent tape 30extends less than halfway or about ⅓ of the way across the horizontalleg 22. In other arrangements, the intumescent tape 30 can extend allthe way across the horizontal leg 22 and/or only partially across thevertical leg 24. However, preferably, at least a portion of theintumescent tape 30 is located on the horizontal leg 22. Such anarrangement results in the intumescent tape 30 being sandwiched, pinchedor compressed between the header track/horizontal leg 22 and the ceilingthereby keeping the intumescent tape 30 in place in the event ofelevated heat or fire. Although heat-resistant adhesive preferably isused to affix the intumescent tape 30 to the angle 20, the adhesive canstill fail at temperatures lower than that required to cause expansionof the intumescent tape 30. By pinching the intumescent tape 30 betweenthe ceiling and the angle 20/header track, the intumescent tape 30 isheld in place even if the adhesive fails.

Preferably, as described above, the intumescent tape or strip 30 isconstructed with a material that expands in response to elevated heat orfire to create a fire-blocking char. One suitable material is marketedas BlazeSeal™ from Rectorseal of Houston, Tex. Other suitableintumescent materials are available from 3M Corporation, HiltiCorporation, Specified Technologies, Inc., or Grace ConstructionProducts. The intumescent material expands to many times (e.g., up to 35times or more) its original size when exposed to sufficient heat (e.g.,350 degrees Fahrenheit). Thus, intumescent materials are commonly usedas a fire block because the expanding material tends to fill gaps. Onceexpanded, the intumescent material is resistant to smoke, heat and fireand inhibits fire from passing through the head-of-wall joint or otherwall joint. Thus, intumescent materials are preferred for manyapplications. However, other fire retardant materials can also be used.Therefore, the term intumescent strip 30 is used for convenience in thepresent specification and that the term is to be interpreted to coverother expandable or non-expandable fire-resistant materials as well,such as intumescent paints (e.g., spray-on), fiberglass wool (preferablywith a binder, such as cured urea-phenolic resin) or fire-rated dry mixproducts, unless otherwise indicated. The intumescent strip 30 can haveany suitable thickness that provides a sufficient volume of intumescentmaterial to create an effective fire block for the particularapplication, while having small enough dimensions to be accommodated ina wall assembly. That is, preferably, the intumescent material strips 30do not cause unsightly protrusions or humps in the wall from excessivebuild-up of material. In one arrangement, the thickness of theintumescent strip 30 is between about 1/16 (0.0625) inches and ⅛ (0.125)inches, or between about 0.065 inches and 0.090 inches. One preferredthickness is about 0.075 inches.

An optional kick-out 34 extending from a free end of the vertical leg 24allows the framing screw to cycle under the angle 20 and also providessome protection to the intumescent strip 30, as is described in greaterdetail below. Preferably, the kick-out 34 extends in the direction ofthe intumescent strip 30 and in a direction opposite the horizontal leg22. The kick-out 34 preferably is also unitary with the vertical leg 24and horizontal leg 22 (i.e., constructed from a single piece ofmaterial). The illustrated kick-out 34 is arcuate in shape. Preferably,the kick-out 34 defines an arc of about 90 degrees or about ¼ of acircle. However, the kick-out 34 may define a variable radius, ratherthan a single radius. The kick-out 34 preferably extends outwardly froman outer surface of the vertical leg 24 by a distance substantiallyequal to or greater than the thickness of the intumescent tape 30.

FIG. 3 illustrates a wall assembly 40 (in particular, a head-of-wallassembly) including an embodiment of the angle 20 installed on each sideof a header track 42. The intumescent strip 30 on the angle 20 iscompressed between the header track 42 and an overhead structure/ceiling44 creating a gasket to protect against smoke, fire and sound passingthrough the gap between the header track 42 and the ceiling 44. In theillustrated arrangement, the ceiling 44 is a concrete deck. However, theangle 20 can be employed with other types of overhead structures,including a fluted pan deck, which is disclosed herein with reference toFIGS. 12 and 13. The wall assembly 40 also includes a plurality of wallstuds 46 (only one is shown), which are coupled to the header track 42by suitable fasteners 48 (e.g., ½ inch framing screws). The header track42 can be a slotted header track, which allows vertical movement of thewall studs 46 relative to the header track 42. Wall board members 50(e.g., drywall) are coupled to the wall studs 46 by suitable fasteners(not shown) and, thus, can move along with the wall studs 46 relative tothe header track 42. The wall board 50 is pressed up against thekick-out 34 to provide a continuous seal against smoke and sound passingthrough the gap between the header track 42/angle 20 and the wall board50.

The header track 42 is secured to the ceiling 44 by a suitable fastener52 (e.g., concrete fastener). If the wall assembly 40 includes a dynamichead-of-wall, a gap may be present between upper ends of the wall studs46 and wall board 50 to allow relative movement therebetween, as shown.The horizontal leg 22 of each angle 20 is interposed between the web ofthe header track 42 and the ceiling 44 such that the angles 20 are heldin place by the header track 42. Compression of the portion of theintumescent strip 30 positioned on the horizontal leg 22 can assist insecuring the angle 20 between the header track 42 and the ceiling 44 andinhibiting or preventing undesired removal of the angle 20. The verticalleg 24 of the angle 20 is interposed between the side leg of the headertrack 42 and the wall board 50. That is, the vertical leg 24 of theangle 20 is positioned on the inside of the wall board 50, whichprovides an attractive finished head-of-wall joint. As described, thekick-out 34 (if present) can contact the wall board 50 to provide aseal. In addition, the kick-out 34 can facilitate entry of the headportion of the fasteners 48 into the gap between the vertical leg 24 andthe side leg of the header track 42 during cycling of the wall studs 46and wall board 50 relative to the header track 42.

Advantageously, such an arrangement permits the use of a separatecomponent (i.e., the angle 20) to carry the intumescent strip 30 insteadof the intumescent strip 30 being placed directly on the header track 42and also permits the angle 20 to be placed inside the wall board 50. Theuse of a separate component (angle 20) to carry the intumescent strip 30can be advantageous because shipping and storage of the angle 20 withoutdamaging the intumescent strip 30 is simplified relative to when theintumescent strip 30 is carried by the header track 42. For example, theangles 20 can be easily stacked and shipped in a box, whereas it is moredifficult to stack and ship a header track 42 incorporating intumescentstrip(s) 30. In addition, the use of a separate component (angle 20) tocarry the intumescent strip 30 allows a fire-rated head-of-wall joint tobe created with nearly any type or brand of header track 42 (or othercomponents).

The angle(s) 20 can be installed before, during or after installation ofthe header track 42. If separate fasteners or fastening methods areused, the angle(s) 20 could be affixed to the ceiling 44 separately andprior to the installation of the header track 42. However, preferably,the angle(s) 20 is/are installed during or after installation of theheader track 42. The angle(s) 20 can be placed on the header track 42and then held in place against the ceiling 44 as the header track 42 issecured to the ceiling 44. Alternatively, the angle(s) 20 can be affixedto the header track 42, even if temporarily (e.g., using an adhesive orcaulk), and then the header and angle(s) 20 can be secured to theceiling 44. Or, the angle(s) 20 can be installed after the header track42 is partially or completely installed. For example, the header track42 can be secured to the ceiling 44 with a minimum number of fasteners52, the angle(s) 20 installed, and then the remaining fasteners 52 canbe installed to secure the header track 42 to the ceiling 44.Alternatively, the header track 42 can be completely installed and thenthe angle(s) 20 can be inserted between the header track 42 and theceiling. The edges of the header track 42 can be slightly flexed toallow insertion of the horizontal leg 22 of the angle 20. The angle(s)20 can be lightly tapped or otherwise pressed into place. If desired, aspacer (e.g., washer or embossment on the upper surface of the track 42)can be positioned between the ceiling 44 and the header track 42 tocreate a small gap (preferably smaller than the combined thickness ofthe horizontal leg 22 and intumescent strip 30) to facilitate insertionof the angle(s) 20. Additional fasteners 52 can be installed throughboth the header track 42 and angle 20, if desired, as shown in FIGS. 10and 11.

In the event of elevated heat or a fire, once a threshold heat has beenreached, the intumescent strip 30 will rapidly expand to fill any gappresent at the head-of-wall, such as between the header track 42 and theceiling 44 and/or between the angle 20/header track 42 and the wallboard 50. The pinching of the intumescent strip 30 between the ceilingand the angle 20/header track 42 assists in keeping the intumescentstrip 30 in place when or if the adhesive used to secure the strip 30 tothe angle 20 degrades to the point that it is no longer effective. Thus,the illustrated wall assembly 40 provides a reliable fire-ratedhead-of-wall joint.

With additional reference to FIGS. 4-6, the top horizontal leg 22 of theangle 20 can be made in different styles to provide a way to secure theleg 22 between the header track 42 and the ceiling 44 and inhibiting orpreventing inadvertent or undesired removal of the angle 20. Asdiscussed above, the angle 20 illustrated in FIGS. 1-3, which includesplanar or flat steel legs 22, 24 will just rely on the compression ofthe intumescent strip 30 between the angle 20 and the overhead structure44 or just the compression/friction of the horizontal leg 22 of theangle 20 between the track 42 and the ceiling 44, for example, if theintumescent strip 30 does not wrap onto the horizontal leg 22. Withreference to FIG. 4, the top leg 22 can be formed (e.g., embossed) witha retention features, such as raised or interference surface features.In particular, the interference surface features may be provided in theform of protrusions or dimples 60 that serve to increase the frictionbetween the angle 20 and the ceiling 44 and/or create interferencecontact between the protrusions 60 and imperfections in the ceiling 44.In any event, the force required to remove the angle 20 (the “removalforce”) can be increased. The raised or interference surface features,protrusions or dimples can be of any suitable shape, preferably which iscapable of being created during a roll forming process. To the extentthat the protrusions/dimples 60 have a longer dimension in one directionthan other directions, the longer dimension preferably extends partiallyor entirely in a lengthwise direction to increase the dimension tendingto resist movement of the angle 20 away from the header track 42(substantially perpendicular to the wall). The protrusions/dimples 60preferably have a height that is less than the thickness of theintumescent strip 30 such that they do not prevent a good seal betweenthe intumescent strip 30 and the ceiling 44. However, in otherarrangements, the protrusion/dimples 60 can be used to create a seal,especially if configured to extend the entire length of the angle 20,and can extend above the upper surface of the intumescent strip 30.

With reference to FIG. 5, the top leg 22 of the angle 20 can have asmall hem 62 so that the angle 20 can be pushed into place and onceproperly installed the hem 62 inhibits or prevents the angle 20 frombeing removed or slipping out due to structure vibrations or movement.As shown, preferably, the hem 62 is a fold in the free end of thehorizontal leg 22 that is positioned above the remaining, preferablyplanar, portion of the horizontal leg 22. Preferably, the hem 62 issubstantially completed folded over; however, in other arrangements, thehem 62 may be a partial fold similar to the kick-out 34, for example.

With reference to FIG. 6, the upper leg 22 can include slots, cut-outsor notches 64 extending from a free end of the leg 22. In onearrangement, the notches 64 are substantially V-shaped (referred toherein as a V-Cut pattern and individually as V-Cuts). The V-Cut pattern64 allows the angle 20 to be flexible so that it could be used on radiuswalls. The V-Cut pattern 64 would also help get around any fasteners 52that are installed to hold the header track 42 in place that may beclose to the outer edge. Features shown in and described with referenceto FIGS. 4-6 can be combined with one another and/or incorporated withthe other angles 20 described herein.

With reference to FIGS. 7-9, the kick-out 34 of the vertical leg 24 canbe done in different styles. For example, with reference to FIG. 7, aquarter-round pattern provides an open end in which the screw 48 cancycle under the angle 20, as described above. In addition, as shown inFIG. 7, the horizontal leg 22 of the angle 20 may not be completely flator planar. Rather, in the illustrated arrangement, the leg 22 defines arecessed portion or recess 68 configured to receive the portion of theintumescent strip 30 positioned on the horizontal leg 22. Preferably,the recess 68 is sized and shaped such that the upper surface of theintumescent strip 30 is positioned above the upper surface of theadjacent portion of the horizontal leg 22 such that a good seal iscreated with the ceiling 44. However, in other arrangements, the uppersurface of the intumescent strip 30 can be flush with or positionedbelow the upper surface of the adjacent portion of the horizontal leg22.

With reference to FIG. 8, the kick-out is in the form of a small hem 70provided on the free end of the vertical leg 24 and includes a first oroutwardly extending portion 72 and a second or return portion 74. Thefirst portion 72 is angled downward from the remaining upper portion ofthe vertical leg 24. The return portion 74 extends back toward theinside of the angle 20, but preferably is either aligned with or stopsshort of the inner surface (extension of the inner surface) of thevertical leg 24 such that interference with the head of the fastener 48is inhibited or eliminated. Thus, the length of the return portion 74 ispreferably less than the length of the outwardly extending portion 72.The intersection of the first and second portions 72, 74 define a corneror rounded surface portion 76 that can contact the wall board 50 tocreate a seal. Preferably, the corner 76 is positioned outwardly of theouter surface of the intumescent strip 30 to provide protection to thestrip 30 during cycling of the wall board 50. However, in otherarrangements, the intumescent strip 30 may extend outwardly beyond thecorner 76. Similar to the kick-out 34 described with reference to FIGS.1-7, the hem 70 also provides an open end for the framing screw 48 tocycle.

With reference to FIG. 9, the kick-out is in the form of a block-out 80.The block-out 80 includes a first portion 82 that extends approximately90 degrees outward from the remaining upper portion of the vertical leg24 and a second portion 84 that extends approximately 90 degreesdownward from the first portion 82. The block-out 80 can also provide anopen end for the screw 48 to cycle. Preferably, the outer surface of theblock-out 80 is positioned outwardly of the outer surface of theintumescent strip 30 to protect the strip 30 during cycling of the wallboard 50. However, the intumescent strip 30 could also extend outwardlyof the block-out 80. Features illustrated in and described withreference to FIGS. 7-9 can be incorporated in other embodiments andversions of the angle 20 described herein.

FIGS. 10 and 11 illustrate a head-of-wall assembly 40 similar to thatshown in and described with reference to FIG. 3 in which a metal studframed wall is attached to a solid concrete deck. Accordingly, the samereference numbers are used to describe the same or correspondingcomponents. FIG. 10 illustrates the head-of-wall joint in a closed(i.e., relatively upward) position and FIG. 11 illustrates thehead-of-wall joint in an open (i.e., relatively downward) position. Inthe illustrated arrangement, optional fasteners 52 (e.g., 1″ concretefasteners) are shown being used to secure the angles 20 in place. Thefasteners 52 pass through both the web of the header track 42 and thehorizontal leg 22 of the angle 20.

Preferably, the header track 42 is installed to the concreteslab/ceiling 44 prior to the intumescent deflection angle 20. Asdescribed, the angle 20 can have an additional fasteners 52 installedthrough the header track 42 and leg 22 of the angle 20 to hold it inplace or it can be a compression friction fit utilizing interferencefeatures 60 (FIG. 4), a small hem 62 (FIG. 5) or the compression on theportion of the intumescent strip 30 that wraps over the corner of theangle 20. FIGS. 10 and 11 illustrate a gap or a space 90 between theoutside leg surface of the header track 42 and the inside surface of thevertical leg 24 of the angle 20 at least at an upper end of the leg 24and, preferably, only at an upper end of the leg 24. This gap 90 has afunction and purpose as it allows the head portion of the framing screw48 to fit between the outside leg surface of the header track 42 and theinside surface of the vertical leg 24 of the angle 20, as shown in FIG.10. This allows the bottom portion of the angle leg 24 to push up tightagainst the outside leg surface of the header track 42 without causingdamage to the intumescent strip 30 or angle 20 during the cycling of thewall assembly or the movement cycle test of the UL 2079 fire-rated walljoint testing protocol. The angle 20 shown in this figure is bent toapproximately an 87 degree angle, but any angle less than 90 degreeswill work. The less-than-90-degree angle is what facilitates thecreation of the gap 90 in the upper corner between the outside leg ofthe header track 42 and the inside surface of the vertical leg 24 of theangle 20, while preferably also maintaining contact between the lowerend of the vertical leg 24 of the angle 20 and an intermediate portionof the leg of the header track 42. The approximately 45 degree (or othersuitable angle) kick-out 34 allows the framing screw 48 to slide up intothe gap 90 between the track 42 and the angle 20 and back out again, foran open deflection joint. However, a gap 90 can also be created with a90 degree angle between the legs 22 and 24 of the angle 20. For example,if a suitable radius is used in the intersection between the horizontalleg 22 and the vertical leg 24, the radius can inhibit or prevent theangle 20 from being placed tightly against the leg of the header track42 thereby creating a gap 90. However, the illustrated arrangement ispreferred because it not only creates a gap 90, but also keeps the lowerend of the vertical leg 24 of the angle 20 in contact with the leg ofthe header track 42.

As described above, FIG. 11 illustrates the head-of-wall assembly 40 inan open position, such as with the deflection gap in a wide openposition with an approximately 1¾ inch gap between the upper ends of thewall board 50 and the ceiling 44. The upper edge of the wall board 50preferably has a tight compression fit against the kick-out 34 toprotect against smoke passage within the fire-rated deflection joint.The framing screw 48 is now located below the vertical leg 24 of theangle 20 and at or near the bottom of the slotted header track 42 whenthe joint is in the open position.

FIGS. 12 and 13 illustrate a wall assembly 40 similar to that shown inand described with reference to FIG. 3 and FIGS. 10 and 11. Accordingly,the same reference numbers are used to describe the same orcorresponding components. In FIGS. 12 and 13, a metal stud framed wallassembly 40 is attached to a ceiling 44 in the form of a fluted pan deck100. The fluted pan deck 100 includes a pan 102, which definesdownwardly-opening spaces, voids or flutes 104, and a layer of concrete106 supported by the pan 102. In the illustrated arrangement, the wallassembly 40 is oriented perpendicular or substantially perpendicular tothe flutes 102 of the fluted pan deck 100. Fire-rated walls requirefire-resistant material, such as mineral wool 110, to be installedwithin the voids 104 of the fluted pan deck 100 when the wall assembly40 is running perpendicular to the flutes 104. The voids or flutes 104of a fluted pan deck 100 vary in size but generally are about 7½ inchesby 3 inches. Mineral wool 110 is compressed and placed into these voids104. A fire spray material 112 (e.g., a fire-resistant elastomericmaterial that can be applied with a sprayer) is then sprayed over thetop of the mineral wool 110 to protect against smoke passage. The firespray 112 will generally have elastomeric qualities to it forflexibility and in some cases may even have intumescent qualities. Intraditional stuff and spray assemblies, the fire spray 112 will go overthe mineral wool 110 and lap over the top edge of the wall board 50, forexample, by about ½ inch.

An aspect of the present invention involves the realization that becausethe fire spray 112 extends over two dissimilar materials, i.e., themineral wool 110 which is compressible and wall board (e.g., drywall) 50which is rigid, a great deal of stress is created in the fire spray 112covering the deflection gap as both materials will act differently asthey are cycled up and down. The mineral wool 110 is flexible and willbe more forgiving as it cycles, but the drywall 50 is rigid and willpull away from the mineral wool 110 and fire spray 112. Therefore, asthese assemblies go through the movement cycle test of UL 2079, the firespray tends to rip or tear along the joint between the drywall and themineral wool. Cracks, rips, or tears create a weak spot in the joint andit becomes very vulnerable to the air-leakage test and burn test thatfollow the movement cycle test according to UL 2079. However, in thearrangement illustrated in FIGS. 12 and 13, it is apparent that the firespray 112 only laps on the intumescent angle 20. The wall board (e.g.,drywall) 50 is able to cycle unencumbered against intumescent angle 20without stress cracks to the fire rated deflection joint. Such anarrangement is capable of providing a Class III Seismic movement jointaccording to UL 2079. Traditional stuff and spays typically are onlycapable of providing Class II Wind Movement according to UL 2079 becausethese types of joints are very vulnerable to cracking or tearing. FIG.12 illustrates the wall in a position in which the upper edges of thewall board 50 are below the fire spray 112 and FIG. 13 shows arelatively more upward position of the wall board 50 in which the upperedge of the wall board 50 partially covers the fire spray 112. In FIG.13, a portion of the wall board 50 and fire spray 112 is removed to showthe other components of the wall.

FIG. 14 illustrates another embodiment of a fire-rated angle 20, whichis similar to the above-described angles 20. Accordingly, the samereference numbers are used to describe the same or correspondingfeatures. The angle 20 of FIG. 14 includes a locking hem 62 on the upperhorizontal leg 22 and another locking hem 120 on the vertical leg 24.The locking hem 62 is similar to the locking hem 62 described inconnection with the angle 20 of FIG. 5. In particular, the free end ofthe locking hem 62 preferably faces toward the vertical leg 24 of theangle 20 to facilitate installation of the angle 20 between the headertrack 42 and the ceiling 44 (especially when the header track 42 hasalready been installed) and inhibit or prevent removal of the angle 20from the installed position. Although the locking hem 62 of thehorizontal leg 22 is positioned above the horizontal leg 22 (between thehorizontal leg 22 and the ceiling 44), it could also be positioned belowthe leg 22. However, engagement of the locking hem 62 with the ceiling44 is believed to provide better resistance to removal of the angle 20than engagement of the locking hem 62 with the header track 42.

The hem 120 on the vertical leg 24 is just one option for the kick-out34. The kick-out 34 allows the framing screw 48 to move up and down,under the angle 20 and back out, as described previously. Preferably,the free end of the hem 120 preferably ends prior to the inner surfaceof the vertical leg 24, or a downward extension or projection of theinner surface, to avoid having the fastener 48 hang up on the free endof the hem 120 as the fastener 48 cycles into and out of the spacebehind the angle 20. The angle 20 of FIG. 14 also includes a narrowerversion of the intumescent strip 30 relative to the prior versions shownin FIGS. 1-13. In the illustrated arrangement, the portion of theintumescent strip 30 positioned on the vertical leg 24 ends short of thehem 120. However, preferably, the width of the intumescent strip 30 onthe vertical leg 24 is equal to or greater than the width of the strip30 on the horizontal leg 22. Preferably, the portion of the intumescentstrip 30 on the vertical leg 24 covers at least about one-half or atleast about two-thirds of the vertical leg 24. In the illustratedarrangement, the intumescent strip 30 covers about two-thirds of thevertical leg 24.

FIGS. 15 and 16 illustrate an angle 20 similar or identical to the angle20 described with reference to FIG. 6 and which includes multiple slots,cut-outs or notches 64, which are in the form of V-Cuts, extending fromthe free end of the upper horizontal leg 22 toward the intersectionbetween the horizontal leg 22 and the vertical leg 24. The V-Cuts 64 canvary in spacing and size. A purpose of the V-Cuts 64 is to allow theangle to be used on a radius wall. The V-Cuts 64 allow the angle 20 tobe bent inward or outward. FIG. 16 shows the V-cuts 64 in an openposition which will happen as the angle 20 is bent. However,advantageously, the intumescent strip 30 will stay intact as the cuts 64preferably are only on a portion of the upper horizontal attachment leg22. Thus, the intumescent strip 30 will still protect against fire andsmoke passage. The V-Cuts 64 (or other types of slots, cut-outs ornotches) may also accommodate/avoid interference with fasteners 52 usedto secure the header track 42 to the ceiling 44.

The illustrated angles 20 are intended for use in combination withheader tracks 42 that are coupled to an overhead structure 44 andreceive upper ends of a plurality of wall studs 46. However, the angles20 can also be used with other types of tracks or other structuralcomponents to create a fire-rated joint. For example, the angles 20could be used with a bottom track or a wall stud. Although not shownherein, as is known, a stud wall commonly includes a bottom track (whichmay be the same as or similar to the illustrated header tracks 42) thatreceives the bottom ends of the wall studs 46 and is secured to thefloor. With respect to the disclosed header tracks 42, these can be of asolid leg variety or can be slotted header tracks, in which each of thefirst side flange and the second side flange includes a plurality ofelongated slots that extend in a vertical direction, or in a directionfrom a free end of the flange toward the web and perpendicular to alength direction of the track. The centerlines of adjacent slots arespaced from one another along a length of the track by a distance, suchas one inch, in one embodiment. However, other offset distances could beprovided, depending on the desired application. Preferably, the slotsare linear in shape and sized to receive and guide a fastener (e.g.,fastener 48) that couples a stud to the header track. The slots allowrelative movement between the header track and the studs. The linearshape of the slots constrains the fasteners to substantially verticalmovement.

As discussed, preferably, the free end of the side flange of the anglesforms a kick-out (e.g., kick-out 34). The kick-out extends outwardlyfrom the remainder of the side flange in a direction away from the topflange (and away from the header track when assembled). One type ofkick-out is an outwardly-bent end portion of the side flange which isoriented at an oblique angle relative to the remaining, preferablyplanar, portion of the side flange. As described herein, the use of theterm side flange (vertical leg or wall portion) can include the kick-outor, in some contexts, can refer to the portion of the side flangeexcluding the kick-out. As described herein, the kick-out functions as alead-in surface for the fasteners that pass through the slots of theheader track when the heads of the fasteners move toward the top of theslots and in between the side flange of the angle and the flange of theheader track. However, the kick-out can be otherwise shaped if desired,depending on the intended application and/or desired functionality. Forexample, the kick-out can be configured to contact the wallboard of anassociated wall assembly to assist in creating a seal between the angleand the wallboard or to inhibit damage to the fire-resistant material onthe angle, as described. Preferred kick-outs can satisfy one or more ofthese functions. In one arrangement, the kick-out extends outwardly lessthan about ¼ inch, less than about ⅛ inch or less than about 1/16 inch.

The illustrated angles are fire-rated components and include afire-resistant material arranged to seal the head-of-wall gap at whichthe angle is installed. Preferably, the fire-resistant material is anintumescent material strip, such as an adhesive intumescent tape. Theintumescent strip is made with a material that expands in response toelevated heat or fire to create a fire-blocking char. The kick-out canextend outwardly a distance greater than the thickness of theintumescent strip, a distance approximately equal to the thickness ofthe intumescent strip, or a distance less than the thickness of theintumescent strip. The size of the kick-out can be selected based onwhether it is desirable for the wall board material to contact thekick-out (e.g., to create a seal or protect the intumescent strip), theintumescent strip, or both the kick-out and the intumescent strip.

The intumescent strip preferably is positioned on one or both of theside flange and the top flange. Thus, one embodiment of an angleincludes an intumescent strip only on the top flange and anotherembodiment of an angle includes an intumescent strip only on the sideflange. However, in the illustrated arrangements, the intumescent stripis attached on both the side flange and the top flange of the angle.Preferably, the intumescent strip covers a substantial entirety of theside flange and also extends beyond the top flange. That is, theintumescent strip preferably extends from the kick-out of the sideflange to the top flange and beyond the top flange. Such an arrangementpermits the intumescent strip to contact the ceiling or other overheadsupport structure to create an air seal at the head-of-wall. Preferably,the upper edge of the intumescent strip wraps around the corner of theangle and is attached to the top flange. Such an arrangement causes theintumescent strip to be pinched between the angle and the ceiling orother overhead support structure to assist in keeping the intumescentstrip in place when exposed to elevated heat, which may cause failure ofan adhesive that secures the intumescent strip to the angle, asdescribed above. However, although less preferred, the upper edge of theintumescent strip could simply extend beyond (above, in the illustratedarrangement) the top flange without being attached to the top flange.

Preferably, a relatively small amount of the intumescent strip ispositioned on the top flange relative to the amount positioned on theside flange. For example, the intumescent strip has a width, which incross-section can be viewed as a length. Preferably, a length of theintumescent strip on the side flange is at least about 3 times thelength of the intumescent strip on the top flange. In one arrangement,the length of the intumescent strip on the side flange is at least about5 times the length of the intumescent strip on the top flange. Inanother arrangement, the length of the intumescent strip on the sideflange is at least about 10 times the length of the intumescent strip onthe top flange. Preferably, the length of the intumescent strip on theside flange is between about ½ inches and 1½ inches and the length ofthe intumescent strip on the top flange is between about ⅛ inches and ½inches. In one preferred arrangement, the length of the intumescentstrip on the side flange is about ¾ inches and the length of theintumescent strip on the top flange is about ¼ inches.

In the illustrated arrangements, the side flange of the angle is shorterthan the flanges of the header track. The side flange of the angle cancover an upper portion of the slots of the header track. Preferably, atleast a lower portion of the slots are exposed or left uncovered by theside flange of the angle. In one arrangement, the length of the sideflange of the angle is about one-half of the length of the flanges ofthe header track. The side flange of the angle can have a length ofbetween about ¾ inches and 3 inches, or between about 1 and 2 inches. Inone arrangement, the side flange of the angle has a length of about 1½inches or 1¼ inches. The flanges of the header track can be any suitablelength. For example, the flanges can be between about 2 and 4 inches inlength, with specific lengths of about 2½ inches, 3 inches, 3¼ inchesand 3½ inches, among others.

The web of the header track can be any suitable width. For example, theweb can have a width between about 2½ and 10 inches, with specificlengths of about 3.5 inches, 4 inches, 5.5 inches, 6 inches and 7.5inches, among others. Preferably, the top flange of the angle is notwider than the web of the header track and, more preferably, is lessthan about ½ the width of the header track. If desired, a thermal breakmaterial can be positioned between any or all corresponding surfaces ofthe angle and the header track. The thermal break material can beapplied to the inner surfaces of the angle. The thermal break materialcan be a liquid applied material, or an adhesively applied sheetmembrane material to provide thermal break insulation to slow down heatpassage during a fire. Any suitable insulating materials can be used.

The header track and the angle can be constructed of any suitablematerial by any suitable manufacturing process. For example, the headertrack and angle can be constructed from a rigid, deformable sheet ofmaterial, such as a galvanized light-gauge steel. However, othersuitable materials can also be used. The header track and the angle canbe formed by a roll-forming process. However, other suitable processes,such as bending (e.g., with a press brake machine), can also be used.Alternatively, the angle could be made from an extruded piece ofmaterial. Preferably, the intumescent strip is applied during themanufacturing process. However, in some applications, the intumescentstrip could be applied after manufacturing (e.g., at the worksite).

As is known, in the wall assembly, one or more pieces of wallboard areattached to one or both sides of the studs by a plurality of suitablefasteners, such as drywall screws. Preferably, the uppermost drywallscrews are positioned close to the header track but spaced sufficientlytherefrom so as to not inhibit complete upward movement of the studsrelative to the header track.

Preferably, in a neutral or unloaded condition, the heads of thefasteners securing the studs to the header track are positioned belowthe lowermost ends, or free ends, of the side flanges of the angle.Preferably, in such a position, an upper end of the wallboard restsagainst the intumescent strip and/or the kick-out. When the wall isdeflected such that the studs move upwardly towards or to a closedposition of the deflection gap, the heads of the fasteners may enter inbetween the flanges of the header track and the side flanges of theangles. If the gap between the flanges is less than the width of thehead of the fastener, the side flanges of the angle may flex or deflectoutwardly to accommodate the heads of the fasteners. The shape and/orangle of the kick-out can facilitate the entry of the heads of thefasteners in between the flanges without getting hung up on the flanges.

FIGS. 17-20 illustrate an alternative angle piece 200 (FIGS. 17 and 18)and a head-of-wall assembly (FIGS. 19 and 20) incorporating the anglepiece 200. The angle piece 200 possesses characteristics that areadvantageous in certain applications relative to the above-describedangle pieces 20 and the prior art arrangements. For example, theabove-described angle pieces 20 position the intumescent strip 30 on anexterior surface of the angle piece 20 such that the intumescent strip30 faces the wall board 50 in an assembled state. In such arrangements,it is usually beneficial for the intumescent strip 30 to cover asubstantial portion of the vertical leg and/or a portion roughly equalto or greater than the maximum possible head-of-wall gap between theupper end of the wall board 50 and the ceiling 44. Such arrangementsassist in maintaining a sealed head-of-wall gap in all deflectionpositions between the maximum head-of-wall gap (fully open position) andthe minimum head-of-wall gap (fully closed position) and avoids damageto the intumescent strip 30 from the upper end of the wall board 50.That is, the upper end of the wall board 50 remains in contact with theouter surface of the intumescent strip 30 at all positions between theminimum and maximum head-of-wall gaps.

However, although such angles 20 and corresponding assemblies provideexemplary performance, the intumescent material used to construct theintumescent strips 30 is an expensive component of the angle pieceassembly. Thus, it would be advantageous from a cost standpoint toreduce the amount of intumescent material used, while maintainingadequate performance or even improving performance. In addition, in someapplications, it is often desirable to utilize a method other than theintumescent strip 30 to create or supplement the seal between the headertrack 42 and the ceiling 44. For example, the assembly of FIGS. 12 and13 illustrates such an arrangement in which a fire spray material 112 isapplied over an upper portion of the angle piece 20. Accordingly, insome such arrangements, it has been discovered by the presentinventor(s) that the portion of the intumescent strip 30 on thehorizontal leg 22 could be omitted. The angle piece 200 andcorresponding assemblies of FIG. 17-20 advantageously reduce the amountof intumescent material employed while at the same time providingadequate or improved performance relative to the above-described anglepieces 20 and corresponding assemblies, as well as the prior artarrangements.

FIGS. 17-20 illustrate an embodiment of a fire-rated profile or anglepiece 200, which is also referred to herein simply as an angle 200,alone (FIGS. 17 and 18) and incorporated into a head-of-wall assembly(FIGS. 19 and 20). The angle 200 preferably is formed from a light gaugesteel material by any suitable process, such as roll forming or bending(such as on a press brake), for example. Preferably, the angle 200 is anelongated member having a consistent or substantially consistentcross-sectional shape throughout its length. One or more preferredembodiments of the angle 200 are generally or substantially L-shaped incross-section. In one embodiment, the angle 200 may be between about 5feet and 25 feet in length. The angle 200 can be between about 10 and 20feet in length. Preferably, the angle 200 is about 10-12 feet in lengthto facilitate shipping and storage. Desirably, the angle 200 issufficiently long to allow installation along a wall with a relativelysmall number of pieces. However, the length of the angle 200 should beshort enough that shipping and material handling is relativelyconvenient. Accordingly, the above-recited lengths are presentlypreferred. However, other lengths may also be used in other situations.

Preferably, the angle 200 includes a top or upper wall portion or top orupper leg or flange 220. The upper wall portion 220 is also referred toherein as a horizontal leg because it is typically oriented in ahorizontal or substantially horizontal plane when installed in ahead-of-wall assembly, as described herein. The angle 200 also includesa side wall portion 240, which is also referred to herein as a verticalleg or flange because it is typically oriented in a vertical orsubstantially vertical plane when the angle 200 is installed in ahead-of-wall assembly. The illustrated vertical leg 240 is unitarilyformed with the horizontal leg 220. That is, the horizontal leg 220 andthe vertical leg 240 are constructed from a single piece of material. Asdescribed above, typically, the single piece of material is a flat pieceof light gauge steel, which is then deformed into the shape of the angle200, such as through a roll-forming, bending (such as on a press brake)or other suitable process. However, in other embodiments, the angle 200could initially be formed in the L-shape or other shape, such as by anextrusion process, for example. Preferably, both the horizontal leg 220and the vertical leg 240 are substantially planar and define an angletherebetween of about 90 degrees. Although 90 degrees is preferred, insome arrangements, the angle could also be somewhat more or somewhatless than 90 degrees. For example, the legs 220 and 240 could define anangle of between about 80 degrees and about 90 degrees, between about 85degrees and 90 degrees or about 87 degrees. This can assist in providinga gap at the upper end of the vertical leg 240 to accommodate a fastenerhead, as is described in greater detail below. Such dimensions of theangle between the legs 220 and 240 assume that the angle 200 is to beused with a header track (or other structure) that defines a generally90 degree angle between the surfaces adjacent a corner (e.g., the weband flange). In alternative arrangements, the angle between the legs 220and 240 can generally match the angle between the surfaces that will beadjacent the angle 200 once installed.

In one embodiment of the light gauge steel angle 200, the horizontal leg220 can define a width 260 (i.e., horizontal cross-sectional dimension)of about ¾ inch or less, 1 inch or less, or 1½ inches or less. In oneembodiment, the vertical leg 240 can define a width or height 280 (i.e.,vertical cross-sectional dimension) between about 1 inch and about 4inches or more depending on amount of fire and smoke protection desiredand/or based on deflection requirements. Preferably, the height 280 isbetween about 2½ to about 3¼ inches. The dimension of the width of thehorizontal leg 220 preferably is selected such that two angles 200 canbe employed in a head-of-wall assembly (FIG. 19) with one angle 200 oneach side of the wall. Preferably, the width of the horizontal leg 220is selected such that the legs 220 of the two angles 200 do not overlapone another when assembled into the head-of-wall assembly. Accordingly,if the angle 200 is configured for use with a wall assembly that iswider than standard width, the width of the horizontal leg 220 can beincreased to, for example, about 1½ inches to about 3 inches, or more.The width or height of the vertical leg 240 is selected such that theleg 240 fills the entire head-of-wall gap, or gap between the ceilingand upper end surfaces of the wall board, in an open-most position ofthe head-of-wall joint (assuming a dynamic joint). In addition,preferably, the width or height of the vertical leg 240 is selected tocover a substantial portion of the corresponding leg of the headertrack. For use with a dynamic joint, it is preferred that the leg 240cover the fastener 48 (if any) in all positions between the open-mostand the closed positions of the joint. Preferably, when used with aslotted header track, the leg 240 covers an entirety or a substantialentirety of the slots of the header track such that the head of thefastener 48 remains underneath the vertical leg 240 in all positions ofthe joint. In view of the above, the actual width or height of thevertical leg 240 can vary from the exemplary widths or heights describedherein.

Preferably, a fire retardant material or a fire retardant materialstrip, such as an intumescent tape or intumescent strip 300, isadhesively (or otherwise) applied to the full length of the fire-ratedangle 200. In a preferred arrangement, the intumescent strip 300 ispositioned on an interior surface of the angle 200. Preferably, theintumescent strip 300 is positioned on an interior surface of thevertical leg 240 of the angle 200. In the illustrated arrangement, theintumescent strip 300 is spaced from a corner 320 of the angle 200 andalso spaced from a free end of the vertical leg 240. That is, theintumescent strip 300 preferably is positioned in an intermediateportion of the interior surface of the vertical leg 240. In otherarrangements, however, the intumescent tape 30 can extend along theentire height of the vertical leg 240. However, such an arrangementwould require a large amount of intumescent material and would be morecostly to manufacture.

The intumescent strip 300 has a strip width, which is a height orvertical dimension 330 as oriented in FIGS. 17-20. As discussed,preferably, the height 330 of the intumescent strip 300 is less than theheight 280 of the vertical leg 240. Preferably, the height 330 of theintumescent strip 300 is less than one-half or, more preferably, is lessthan about one-third of the height 280 of the vertical leg 240. In onearrangement, the height 330 can be about one-seventh of the height 280.As described above, preferably, the intumescent strip 300 is spacedbelow the corner 320 of the angle 200 to define a spaced distance 340between the upper end of the intumescent strip 300 and an upper end ofthe interior surface of the vertical leg 240. Furthermore, theintumescent strip 300 is also spaced above the free end of the verticalleg 240 to define a spaced distance 350 between the lower end of theintumescent strip and a lower end of the interior surface of thevertical leg 240. In the illustrated arrangement, the distance 340 isless than the distance 350. In other words, the intumescent strip 300 ispositioned closer to the upper end of the vertical leg 240 than thelower end of the vertical leg 240. Such an arrangement advantageouslypermits expansion of the intumescent strip 300 in both upward anddownward directions, while also avoiding contact between the fastener 48and the intumescent strip 300 during at least a significant portion ofthe movement of the dynamic joint and, possibly, during the entiremovement of the dynamic joint.

Preferably, the height 330 of the intumescent strip 300 is generallyrelated to and can be varied with the amount of movement provided by thedynamic joint. That is, the larger the maximum movement allowed by thedynamic joint, the greater the height 330. For example, in somearrangements, the height 330 of the intumescent strip 300 is aboutone-half or less of the maximum movement allowed by the dynamicdeflection joint. In some arrangements, the height 330 is approximatelyor exactly one-half of the maximum movement allowed by the dynamicjoint. For a 1½ inch dynamic joint, the height of the intumescent strip300 can be approximately ¾ inch. The distance 340 can be about one-halfthe height 330 of the intumescent strip 300 (e.g., ⅜ inch) and thedistance 350 can be about twice the height 330 (e.g., 1½ inch). Forlarger or smaller dynamic joints, these dimensions can be scaledappropriately or the distance 340 can remain ⅜ inch or about one-halfthe height 330 and the other dimensions can vary as necessary. Thus, asdescribed above, the angles 20 generally include an intumescent strip 30that is at least as wide as the maximum dynamic joint movement; however,the preferred angles 200 can employ generally one-half the amount ofintumescent material for the same dynamic joint thereby significantlylowering the manufacturing costs.

Preferably, as described above, the intumescent tape or strip 300 isconstructed with a material that expands in response to elevated heat orfire to create a fire-blocking char. One suitable material is marketedas BlazeSeal™ from Rectorseal of Houston, Tex. Other suitableintumescent materials are available from 3M Corporation, HiltiCorporation, Specified Technologies, Inc., or Grace ConstructionProducts. The intumescent material expands to many times its originalsize (e.g., up to 35 times or more) when exposed to sufficient heat(e.g., 350 degrees Fahrenheit). Thus, intumescent materials are commonlyused as a fire block because the expanding material tends to fill gaps.Once expanded, the intumescent material is resistant to smoke, heat andfire and inhibits fire from passing through the head-of-wall joint orother wall joint. Thus, intumescent materials are preferred for manyapplications. However, other fire retardant materials can also be used.Therefore, the term intumescent strip 300 is used for convenience in thepresent specification and that the term is to be interpreted to coverother expandable or non-expandable fire-resistant materials as well,such as intumescent paints (e.g., spray-on), fiberglass wool (preferablywith a binder, such as cured urea-phenolic resin) or fire-rated dry mixproducts, unless otherwise indicated. The intumescent strip 300 can haveany suitable thickness that provides a sufficient volume of intumescentmaterial to create an effective fire block for the particularapplication, while having small enough dimensions to be accommodated ina wall assembly. That is, preferably, the intumescent material strips300 do not cause unsightly protrusions or humps in the wall fromexcessive build-up of material. In one arrangement, the thickness of theintumescent strip 300 is between about 1/16 (0.0625) inches and ⅛(0.125) inches, or between about 0.065 inches and 0.090 inches. Onepreferred thickness is about 0.075 inches.

FIGS. 19 and 20 illustrate a wall assembly 400 similar to that shown inand described with reference to FIGS. 12 and 13, except the angle 20 isreplaced by the angle 200 of FIGS. 17 and 18. Accordingly, the samereference numbers are used to describe the same or correspondingcomponents of the wall assembly other than the angle 200. The wallassembly 400 can be constructed in the same manner as the wallassemblies 40 described above. In FIGS. 19 and 20, a metal stud framedwall assembly 400 is attached to a ceiling 44 in the form of a flutedpan deck 100. The fluted pan deck 100 includes a pan 102, which definesdownwardly-opening spaces, voids or flutes 104, and a layer of concrete106 supported by the pan 102. In the illustrated arrangement, the wallassembly 400 is oriented perpendicular or substantially perpendicular tothe flutes 102 of the fluted pan deck 100. As described above, afire-resistant material, such as mineral wool 110, typically isinstalled within the voids 104 of the fluted pan deck 100 when the wallassembly 400 is running perpendicular to the flutes 104. The voids orflutes 104 of a fluted pan deck 100 vary in size but generally are about7½ inches by 3 inches. Mineral wool 110 is compressed and placed intothese voids 104. The mineral wool 110 can be a mineral wool pillowmarketed by Rectorseal or a mineral wool plug marketed under the tradename Delta Plug. The mineral wool pillow includes an intumescentmaterial coating over the mineral wool material core and the entirepillow is encapsulated in a plastic outer lining.

A fire spray material 112 (e.g., a fire-resistant elastomeric materialthat can be applied with a sprayer) is then sprayed over the top of themineral wool 110 to protect against smoke passage. The fire spray 112will generally have elastomeric qualities to it for flexibility and insome cases may even have intumescent qualities. In traditional stuff andspray assemblies, the fire spray 112 will go over the mineral wool 110and lap over the top edge of the wall board 50, for example, by about ½inch. However, as described above, because the fire spray 112 extendsover two dissimilar materials, i.e., the mineral wool 110 which iscompressible and wall board (e.g., drywall) 50 which is rigid, a greatdeal of stress is created in the fire spray 112 covering the deflectiongap as both materials will act differently as they are cycled up anddown. The mineral wool 110 is flexible and will be more forgiving as itcycles, but the drywall 50 is rigid and will pull away from the mineralwool 110 and fire spray 112. Therefore, as these assemblies go throughthe movement cycle test of UL 2079, the fire spray tends to rip or tearalong the joint between the drywall and the mineral wool. However, inthe arrangement illustrated in FIGS. 19 and 20, it is apparent that thefire spray 112 only laps on the intumescent angle 200. The wall board(e.g., drywall) 50 is able to cycle unencumbered against intumescentangle 200 without stress cracks to the fire rated deflection joint. Suchan arrangement is capable of providing a Class III Seismic movementjoint according to UL 2079. FIG. 19 illustrates the wall in a positionin which the upper edges of the wall board 50 are below the fire spray112 and FIG. 20 shows a relatively more upward position of the wallboard 50 in which the upper edge of the wall board 50 partially coversthe fire spray 112. In FIG. 20, a portion of the wall board 50, firespray 112 and angle 200 is removed to show the other components of thewall.

Advantageously, in the illustrated arrangement, the fire spray 112(along with the mineral wool 110 in the flutes 104) creates a sealbetween the ceiling 44 and the angle 200. In addition, contact betweenan inner surface of the wall board 50 and the angle 200 creates a sealthat inhibits or prevents the passage of air or smoke between the headertrack 42 and the wall board 50. That is, the vertical leg 240, as in theprior arrangements, is adjacent the header track 42. In this context,adjacent means that the wall board 50 is not interposed between thevertical leg 240 and the header track 42. However, in some arrangements,other materials or components may be positioned between the vertical leg240 and the header track 42. In the illustrated arrangement, because thevertical leg 240 extends along a substantial length of the leg of theheader track 42, there is a substantial distance of overlap between thewall board 50 and the angle 200, thereby enhancing the sealtherebetween. In addition, preferably, the head portions of thefasteners 48 that secure the studs 46 to the header track 42 remainunderneath the vertical leg 240 of the angle 200 in all positionsbetween the minimum and maximum deflection joint positions. Thus, nokick-outs or other structures are necessary to allow entry of thefastener heads into the space between the angle 200 and the header track42. Advantageously, this simplifies the construction of the angle 200and, if desired, permits a brake press machine to be used in the placeof a roll forming process thereby reducing tooling costs and, thus,reducing the final cost of the angle 200. As described above, with theillustrated arrangement, it is not necessary for the intumescent strip300 to extend the entire height of the maximum deflection joint gap.Thus, less intumescent material can be used to further reduce the costof the angle 200. Moreover, because contact is between the wall board 50and the angle 200 (instead of the header track 42), the header track 42can be configured for drift movement (e.g., movement in a longitudinaldirection of the track 42) without a reduction in the performance of thehead-of-wall seal.

FIGS. 21 and 22 are schematic illustrations of the wall assembly 400 intwo different positions of the deflection gap. FIG. 21 illustrates thewall assembly 400 in a relatively more closed position (i.e., smallergap) compared to the relatively more open position (i.e., larger gap)shown in FIG. 22. Preferably, in each position, the head of the studfastener 48 is underneath the vertical leg 240 of the angle 200. Withrespect to the positioning of the intumescent strip 300 on the angle200, it is not necessary that the intumescent strip 300 is positionedhigh enough to avoid all contact with the head of the fasteners 48 in aclosed position of the deflection joint (FIG. 21). The intumescent strip300 is not relied upon for air/smoke sealing purposes, so even if minordamage is sustained at the location of each fastener head, performancewill not be significantly impacted. In addition, under typicalconditions, full closure of the dynamic deflection joint does not occurwith great frequency.

FIGS. 23 and 24 are schematic illustrations of the wall assembly 400before and after expansion of the intumescent material strip 300,respectively. As illustrated, in FIG. 23, prior to any significantexpansion of the intumescent material strip 300, the strip 300 isrelatively thin and, preferably, positioned toward the upper end of thevertical leg 240 of the angle 200. Accordingly, the presence of theintumescent strip 300 does not cause unsightly bulging of the angle 200or upper end of the wall board 50. In addition, preferably, theintumescent strip 300 is positioned out of the way of (e.g., above) thehead portion of the stud fasteners 48 in many positions of the dynamicdeflection joint such that relatively free movement of the deflectionjoint is permitted. FIG. 24 illustrates the wall assembly 400 after atleast partial expansion of the intumescent strip 300. The intumescentstrip 300 expands in a vertical direction to partially or completelyfill the space between the vertical leg 240 of the angle and the headertrack 42. The expanded intumescent strip 300 may push the vertical leg240 of the angle outwardly against the wall board 50 to assist inmaintaining a seal between the wall board 50 and the angle 200.Preferably, the horizontal leg 220 is captured between the header track42 and the ceiling 44 to, along with the fire spray 112 and the wallboard 50 holding the lower end of the vertical leg 240, inhibit orprevent separation of the angle 200 from the header track 42 in responseto the expansion of the intumescent strip 300. The expanded intumescentmaterial 300 slows the transfer of heat through the head-of-wall gap ordeflection joint.

FIGS. 25-27 illustrate alternative embodiments of the angle 200, whichare similar to the angle 200 of FIGS. 17-24. Accordingly, the samereference numbers are utilized to indicate the same or correspondingcomponents. In addition, for the sake of convenience, only thedifferences relative to the angle 200 are discussed. The angle 200 ofFIG. 25 positions the intumescent strip 300 closer to the upper end ofthe vertical leg 240 and, in some arrangements, positions theintumescent strip 300 at the upper end of the vertical leg 240 such thatthe upper end of the intumescent strip 300 is adjacent the corner 320.In such an arrangement, the intumescent strip 300 is less likely tointerfere with the movement of the stud fasteners 48. However, expansionof the intumescent strip 300 generally occurs only in the downwarddirection. Accordingly, the angle 200 of FIG. 25 is well-suited for usein smaller deflection joint applications. The angle 200 of FIG. 26 issimilar to the angle 200 of FIG. 25 except that a second intumescentstrip 300 is positioned on an exterior surface of the angle 200,preferably on an exterior surface of the horizontal leg 220. In theillustrated arrangement, the second intumescent strip 300 is positionedadjacent the corner 320 and has a width that is less than the width ofthe horizontal leg 220. However, in other arrangements, the secondintumescent strip could extend the entire width of the horizontal leg220 or could be positioned away from the corner 320, such as in anintermediate location or adjacent the free end of the horizontal leg220. The second intumescent strip 300 can provide a seal or assist inproviding a seal with the ceiling 44 and is especially well-suited forflat concrete deck applications or other applications where additionalsealing or additional intumescent 300 is desired. The angle 200 of FIG.27 is similar to the angle 200 of FIG. 26, except that the secondintumescent strip 300 is positioned in a recess defined along an edge ofthe horizontal leg 220 near or adjacent the corner 320. Such anarrangement can facilitate insertion of the horizontal leg 220 betweenthe header track 42 and the ceiling 44.

FIG. 28 illustrates a wall assembly 400 similar to the wall assembly 400of FIGS. 19-24. Accordingly, the same reference numbers are utilized toindicate the same or corresponding components. In addition, onlydifferences relative to the wall assembly 400 of FIGS. 19-24 arediscussed in detail. In the wall assembly 400 of FIG. 28, the angle 200preferably does not incorporate an intumescent material strip 300.Rather, the wall assembly of FIG. 28 utilizes the concepts of creatingan air/smoke seal with the angle 200 and fire spray 112. In theillustrated arrangement, the fire spray 112 extends along a substantialportion or along the entirety of the vertical leg 240 of the angle 200.However, the fire spray 112 could also extend only along the upperportion of the vertical leg 240. Preferably, a fire-retardant material,such as mineral wool, is positioned within the header track 42 and abovethe studs 46 to slow the transfer of heat through the deflection gap ina manner similar to the intumescent strip 30, 300 utilized in theabove-described wall assemblies 40, 400. In an alternative arrangement,the angle 200 could be omitted and the fire spray 112 could be applieddirectly to the leg of the header track 42. Preferably, in such anarrangement, the side flange or leg of the header track 42 wouldincorporate a sealing structure, such as an elongated protrusion, tocreate a seal between the wall board 50 and the header track 42.

FIG. 29 illustrates an alternative embodiment of the angle 200, which issimilar to the angle 200 shown in FIGS. 17-27. Accordingly, the samereference numbers are utilized to indicate the same or correspondingcomponents. In addition, for the sake of convenience, only thedifferences relative to the angle 200 are discussed. The angle 200 ofFIG. 29 positions a first intumescent strip 300 on the vertical leg 240and a second intumescent strip 300 on the horizontal leg 220. In such anarrangement, the intumescent strips 300 keep the entire angle 200 spacedaway from the track 42 to further reduce heat transfer between the metalcomponents. Additionally, using only strips of intumescent materialinstead of fully lining the inside surfaces of the angle 200 withintumescent material achieve the desired result at a low cost becausethe intumescent material is very expensive compared to metal. Ifdesired, additional intumescent material or strips could be provided.For example, an intumescent material strip 300 could be positioned on anupper surface of the web 220, as shown in FIGS. 26 and 27. Such a strip300 can provide a gasket function to seal a gap between the angle 200and the ceiling 44, which can be caused by imperfections orirregularities of the ceiling 44 surface. That is, the ceiling 44surface may not be completely flat or planar, as can be the case withpoured concrete decks, for example. In addition, if only a sealingfunction is desired, the strip 300 may not be intumescent or expandablematerial. Moreover, other intumescent materials (e.g., paint) can beused in the place of the illustrated strips 300.

FIG. 30 illustrates a wall assembly 400 similar to the wall assembly 400of FIGS. 19-24 and 28. Accordingly, the same reference numbers areutilized to indicate the same or corresponding components. In addition,only differences relative to the wall assembly 400 of FIGS. 19-24 and 28are discussed in detail. In the wall assembly 400 of FIG. 30, the angle200 incorporates two intumescent material strips 300, which preferablyspace the angle 200 from the header track 42 to create an insulationspace (e.g., air space) therebetween.

As illustrated, the wall assembly 400 includes two angles 200. In someembodiments, the wall assembly 400 may include one angle 200 such aswhen the header track 42 is not a slotted header track.

Fire-Block Expansion Joint

FIG. 31 illustrates a wall and window assembly incorporating anembodiment of a fire-blocking drift joint assembly 500 extendinglengthwise in a vertical gap between a window mullion 510 and wallassembly 511. The fire-blocking drift joint assembly 500 may include apair of fire-blocking drift elongate members or joints 520 installedbetween the window mullion 510 and the wall assembly 511. The driftjoint assembly 500 is illustrative of one of the various possibleapplications of a fire-blocking drift joint. It can be appreciated byone of skill the art that many other types of architectural jointsbesides those between window mullions and walls could benefit from theadvantages of the fire-blocking drift joints described herein. In theembodiment shown in FIG. 31, the wall assembly 511 comprises metal studs516, footer and header tracks (not shown), and drywall panels 513 and514. In some embodiments, wall assembly 511 could also be a wood-studdedwall. In the embodiment shown in FIG. 31, the wall assembly 511 is widerthan window mullion 510. The fire-blocking drift joints 520 may be usedto create a fire-seal partition across the interface or gap 517 betweenthe wall assembly 511 and the window mullion 510 despite the differencesin width between the mullion 510 and the wall assembly 511.

Additionally, window mullion 510 may be designed to allow for lateral,horizontal, or vertical drift movement or some combination of all threeof these movements relative to the wall assembly 511. As discussedabove, it is desirable to maintain a fire-seal partition from one sideof the wall assembly 511 to the other side of the wall assembly 511. Inorder to maintain a cohesive fire-seal partition, the interface 517should maintain the same fire-seal partition as the rest of the wallassembly 511 and the window mullion 510. Use of a fire-blocking driftjoint 520, as described herein, can allow for movement between thewindow mullion 510 and the wall assembly 511 while maintaining acohesive fire-seal partition across the interface 517. As illustrated inFIG. 31, window mullion 510 acts as an interface between the wallassembly 511 and a glass curtain 512. Because of the differences inmovement between the wall assembly 511 and the window mullion 510 whichis connected to the glass curtain 512, it is advantageous to allow foran interface 517 between the window mullion 510 and the wall assembly511. However, to maintain a fire-seal partition from one side of wallassembly 511 to the opposite side of wall assembly 511 including theinterface 517, one or more fire-blocking drift joints 520 may be used

FIG. 32 illustrates an embodiment of the fire-blocking drift joint 520of FIG. 31 shown in profile view. As illustrated, the fire-blockingdrift joint 520 is comprised of a central body 521 having first end 522and a second end 526. The central body 521 may be made from a lightgauge flat piece of sheet steel, or other suitable metal or othermaterial as described above. Alternatively, the central body 521 may bemade from two pieces of light gauge flat sheet steel that aremechanically fastened together between the first end 522 and the secondend 526, such as by Snap-On connections, interlocking hems, tongue andgroove joints, or welding or by any other mechanical fastening meansfamiliar to one of ordinary skill in the art.

With continued reference to FIG. 32, fire-blocking drift joint 520further comprises a compressible section 524 between the ends 522 and526. Compressible section 524 is designed as an elastic unit that may becompressed or extended and can exert a force to return to its neutralstate. As described above, in some embodiments, the compressible section524 may comprise legs 524 a and 524 b that come together to form anangle that may be V-shaped or U-shaped or any other profile that one ofordinary skill in the art would recognize as having the desirableelastic compressible properties. Compressible section 24 further has anexterior side 525 b and interior side 525 a. In some embodiments a fireretardant material (not shown) may be attached to either the exteriorside 525 b or the interior side 525 a or both sides of compressiblesection 524. This fire retardant material may partially or completelycover one or both sides of the compressible section 524.

In some embodiments, the first end 522 and second end 526 of thefire-blocking drift joint 520 further includes an attachment flange 523and a non-attachment flange 527, respectively. In the illustratedembodiment, the attachment flange 523 may be about 1½ inches long butthe length of this flange can vary widely depending on the jointinterface application. In some embodiments, flanges 523 and 527 are flatsections of sheet metal, but in other embodiments the flanges may becurved or bent to accommodate the geometry of prospective attachmentsurfaces. In some embodiments, the non-attachment flange 527 has a stripof compressible fire retardant material 528 facing outward so that thefire retardant material 528 can press against or contact non-attachmentsurfaces to maintain the fire partition seal. The fire retardantmaterial 528 may be any type of fire retardant material, such as anintumescent tape or strip or intumescent paint or others as describedherein.

With references to FIGS. 31 and 32, it can be seen that the drift joint520 may be inserted into the interface 517. Drift joint 520 may beinserted into interface 517 in a compressed state with compressiblesection 524 in a compressed state. Alternatively, the drift joint 520may be inserted in a neutral elastic state. Preferably, drift joint 520is held in place in interface 517 in a compressed state. To this end,drift joint 520 may be sized to be placed into interface 517 in acompressed state whereby intumescent strip 528 and non-attachment flange527 are pressed tightly against drift surface 518 of window mullion 510.The tight fit of the drift joint 520 within the interface 517 helpsmaintain the fire-seal partition. The drift joint 520 is then held inplace by securing attachment flange 523 to the metal stud 16 of the wallassembly 511. In some installations, the first end 522 of the driftjoint 520 is inserted into the gap 515 between the drywall 514 and themetal stud 516 and coupled via mechanical or adhesive fasteners toattachment surface 519 of metal stud 516. In this manner, the driftjoint 520 may be secured to the wall assembly 511 while thenon-attachment flange 527 is pressed tightly against drift surface 518of window mullion 510. In some embodiments, when the mullion 510 moveslaterally, the compressive force provided by the compressible section524 presses the non-attachment flange 527 against the drift surface 518of the mullion 510, even as the mullion 510 moves. In some embodiments,when the mullion 510 drifts vertically or horizontally relative to thewall assembly 511, the compressible section 524 presses thenon-attachment flange 527 against the drift surface 518 and the end 526slidingly engages drift surface 518. The fire-seal partition may thus bemaintained across interface 517, despite the relative movement of thefirst and second structures.

In some embodiments, the intumescent strip 528 is on an exterior surfaceof the non-attachment flange 527 such that it is located between thedrift surface 518 and the non-attachment flange 527 when installed. Inother embodiments, the intumescent strip 528 may be attached to the end526 but not directly in contact with drift surface 518 because of thecurvature or bends in central body 521 optionally included innon-attachment flange 527.

FIG. 33 illustrates a profile view of another embodiment of afire-blocking drift joint having an angle α between the non-attachmentflange 527 and the attachment flange 523. FIG. 33 illustrates a fireblocking drift joint similar to that shown in and described withreference to FIG. 32. Accordingly, the same reference numbers are usedto describe the same or corresponding components. This embodiment isdesigned to accommodate the geometry of different joint structures. Inthe embodiment shown in FIG. 33, the angle α is approximately 90°.Alternatively, angle α may be approximately 45°, approximately 60°,approximately 135°, approximately 180°, or any angle between 0° and360°. One of ordinary skill in the art can appreciate that angle α isdefined by the geometries of the surfaces of the first structure and thesecond structure. Attachment flange 523 or 527 may be set at any angleto accommodate the geometry of the joint interface. As an example, inFIG. 31, attachment flange 523 is parallel to attachment surface 519 tomake mechanical attachment simple and non-attachment flange 527 isparallel to drift surface 518 to ensure that the intumescent strip 528is pressed firmly against the drift surface 518 of the mullion 510 tomaintain the fire-seal partition across interface 517. As anotherexample, non-attachment flange 527 and attachment flange 523 may beapproximately parallel as shown in FIG. 32. In other embodiments, asshown in FIG. 34, the second end 526 may not include a flatnon-attachment flange. Attachment flange 523 may be set at any anglerelative to the non-attachment flange 527 to accommodate the geometry ofthe joint interface.

FIG. 34 illustrates a profile view of an embodiment of a fire-blockingdrift joint in the form of a double ply drift joint. FIG. 34 illustratesa fire blocking drift joint similar to that shown in and described withreference to FIG. 32. Accordingly, the same reference numbers are usedto describe the same or corresponding components. In this embodiment,the central body 521 is bent back against itself and doubled over tocreate a double ply compressible section 524 having an interior-facingwall or layer 542 and an exterior-facing wall or layer 543 separated bya space 544. In this embodiment, the compressible section may have fourlegs 524 a-524 d that come together in pairs to form angles that may beV-shaped or U-shaped, or even a combination of the two different shapes.In some embodiments, the space 544 may be filled with a fire-retardantmaterial 546, such as intumescent strips or other fire-retardantmaterials. Alternatively, fire retardant material 546 may be attached tosheet 542 on interior-facing surface 525 a of the compressible section524 or sheet 543 on exterior-facing surface 525 b of the compressiblesection 524.

Furthermore, in the embodiment shown in FIG. 34, the second end 526 doesnot include a flat non-attachment flange 527 as shown in FIGS. 31-33. Inthis embodiment, second end 526 is pressed against or contacts a movingsurface, such as drift surface 518 in FIG. 31, to allow vertical,horizontal and lateral movement between a first structure and a secondstructure. Alternatively, the fire-blocking drift joint 520 in FIG. 34can optionally include a flat non-attachment flange similar tonon-attachment flange 527 as shown in FIGS. 31-33 and FIG. 35.

FIG. 35 illustrates an embodiment of a fire-blocking drift joint in theform of a double ply fire-blocking drift joint with second end 26 and anon-attachment flange 27. FIG. 35 illustrates a fire blocking driftjoint similar to that shown in and described with reference to FIG. 32.Accordingly, the same reference numbers are used to describe the same orcorresponding components. In this embodiment, the central body 521 isbent back against itself and doubled over to create a double plycompressible section 524 having an interior-facing sheet 542 and anexterior-facing sheet 543 separated by a space 544. In some embodiments,the space 544 may be filled with a fire-retardant material 546, such asintumescent strips or other fire-retardant materials. Alternatively,fire retardant material 546 may be attached to sheet 542 oninterior-facing surface 525 a of the compressible section 524 or sheet543 on exterior-facing surface 525 b of the compressible section 524.Alternatively, in some embodiments, central body 521 may consist of twosheets of light gauge steel that are mechanically attached either atsecond end 526 or elsewhere between second end 526 and first end 522.This attachment may be by any suitable mechanical means such as thosediscussed above.

FIG. 36 illustrates an embodiment of a profile view of an fire-blockexpansion joint 600 having a central body 661 and first and second ends662 and 663, attachment flanges 668 and 669, and compressible section664. Each of the elements described in the foregoing embodiments of thefire-blocking drift joints shown in FIGS. 31-35 may be also beoptionally incorporated into the embodiments of the fire-block expansionjoints illustrated in FIGS. 36-38 and described herein. As shown in FIG.36, attachment flanges 668 and 669 are preferably flat and 1½ to 3inches long, but the length of this flange can vary depending on thejoint interface application. Alternatively, attachment flanges 668 and669 may be curved or otherwise bent to accommodate the geometry of theprospective mounting surfaces to first and second structures as would beunderstood by one of ordinary skill in the art. Attachment flanges 668and 669 may also be prepared to receive mechanical fasteners as hereindescribed by being pre-slotted or punctured. In some embodiments,attachment flanges 668 and 669 include a strip of compressible fireretardant material, such as intumescent strips or tape. Thefire-retardant material preferably faces outward so that the fireretardant material can press against or contact the attachment surfacesto maintain the fire partition seal. The central body 661 is preferablymade from a single sheet of a light gauge flat piece of sheet steel orother suitable metal or other material as described above.

With continued reference to FIG. 36, the fire-blocking expansion joint600 further comprises a compressible section 664 between the ends 663and 662. Compressible section 664 is designed as an elastic unit thatmay be compressed or extended and can exert a force to return to itsneutral state. As described above, in some embodiments, the compressiblesection 664 may comprise legs 664 a and 664 b that come together to forman angle that may be either V-shaped or U-shaped or any other profilethat one of ordinary skill in the art would recognize as having thedesirable elastic compressible properties.

In some embodiments, fire retardant material 666 may be attached toexpansion joint 600 as an additional fire-blocking mechanism. Asillustrated in FIG. 36, fire retardant material 666 is mounted to theexterior surface 665 b of compressible section 664. Alternatively, thefire retardant material 666 may be mounted to the interior surface 665 aof compressible section 664, or to both interior and exterior surfaces665 a and 665 b. In some embodiments, fire retardant material 666 mayextend to cover the length of both legs forming the compressible section664, or, as shown in the embodiment of FIG. 36, may cover only a portionof compressible section 664.

FIG. 37 illustrates a profile view of a double ply fire-block expansionjoint 70 with two ends 662 and 663 and two attachment flanges 668 and669. FIG. 37 illustrates a fire blocking drift joint similar to thatshown in and described with reference to FIG. 36. Accordingly, the samereference numbers are used to describe the same or correspondingcomponents. The double ply compressible section 774 is made from asingle sheet of light gauge steel bent over itself to form an exteriorlayer 773 and an interior layer 772. Alternatively, as described abovewith respect to central body 521, central body 661 may similarlycomprise two pieces of metal mechanically fastened together. In theembodiment shown in FIG. 37, the exterior layer 773 extends the lengthof compressible section 774. The exterior layer 773 may optionallyextend the full length of the joint 700 to the end 662. Alternatively,exterior layer 773 may extend partially through the length ofcompressible section 774. A space 744 may be created between exteriorlayer 773 and interior layer 772. Fire retardant material 776 mayoptionally be used to fill the space 744. In the embodiment shown inFIG. 37, the entirety of space 744 within compressible section 774 isfilled with fire retardant material 776. Optionally, fire retardantmaterial 776 may partially fill space 744. Alternatively, fire retardantmaterial can be used in space 744 between exterior layer 773 andinterior layer 772 and may also be applied within the space between thetwo layers forming the attachment flange 669 or at any point betweenexterior layer 773 and interior layer 772 depending on the length of thetwo-ply section of the joint 70.

With continuing reference to FIG. 37, the fire retardant material 776may be any type of intumescent material such as intumescent tape orstrips or intumescent paint. The fire retardant material 776 may beinstalled on the interior surface 775 a of the compressible section 774or may be installed on the exterior surface 775 b, or on both surfaces775 a and 775 b.

In some embodiments, attachment flanges 668 and 669 can be flat metalextensions. They may also be bent or curved to more closely matchsurfaces of the first and second structures to which they will bemounted. Additionally, attachment flanges 668 and 669 may optionally beprepared to receive mechanical fasteners such as those described above.

As shown in FIG. 37, attachment flange 668 is single ply or a singlelayer. Alternatively, the central body 661 may be bent such thatexterior layer 773 extends partially onto or across attachment flange668, thus making it a double ply attachment flange similar to theattachment flange 669 shown in FIG. 37. Alternatively, attachment flange669 may be single ply and attachment flange 668 may be double ply.

With continuing reference to FIG. 37, fire-blocking expansion joint 700may include an angle β between attachment flanges 668 and 669. As shownin FIG. 37 the angle β is approximately 90°. However one of ordinaryskill in the art could also appreciate that this angle can be varied toaccommodate diverse geometries of prospective mounting surfaces ondifferent first and second structures as described above with respect toFIGS. 31-35. As an example, attachment flange 668 may be approximatelyparallel to attachment flange 669.

FIG. 38 illustrates a header block assembly 800 including two fire-blockexpansion joints 600, 700 installed within a horizontal head-of-wall gapbetween a CMU concrete block wall 820 and a ceiling I-beam 850 sprayedwith fireproofing material 860. As shown in FIG. 38, fire-blockexpansion joints 600 and 700 are installed across interface 870 betweenheader block 840 attached to the CMU concrete block wall 820 and I-beam850. The illustrated assembly allows for lateral movement between theconcrete block wall 820 and I-beam 850 while maintaining a fire sealpartition across interface 870. The fire-block expansion joints may beany of the embodiments discussed above in FIGS. 31-37. As illustratedjoint 700 may be similar to the two-ply joint shown in FIG. 37 and thejoint 600 may be similar to the joint shown in FIG. 36. In otherembodiments, two of the same fire-blocking joints may be used to sealthe interface 870.

On the CMU side, fire-block expansion joints 600 and 700 may bemechanically fastened, such as by fastening units 801, to header 840through the attachment flange 668. On the I-beam side, I-beam 850 iscovered in fireproofing insulation 860. In this illustrative embodiment,to connect fire-block expansion joints 600 and 700 at their second endsthrough the attachment flanges, Z furring 880 is installed on I-beam 850by means of mechanical fasteners such as clips or other fastener as isgenerally known by those of ordinary skill in the art. This allowsI-beam 850 to be uniformly coated with fireproofing insulation 860 andstill be connected to fire-block expansion joints 600 and 700.Alternatively, the attachment flange is either connected directly toI-beam 850 or to insulation 860 at surface 910 through mechanical meansor adhesives as described herein.

As illustrated in the assembly view of FIG. 38, fire retardant material660 may optionally be applied to the interior side of brackets facinginterior space 890, as discussed above with reference to FIG. 36. Thefire retardant material 660 may be factory installed or installed byhand onto the surface of expansion joint 600. In the header blockassembly view shown in FIG. 38, the fire retardant material 660 wouldnot be visible from the exterior side of the assembly. Alternativelyfire retardant material 660 may be applied to the exterior side ofexpansion joint 600, or be applied to both the interior and exteriorsides of the fire block expansion joints.

In some embodiments, expansion joints 700 and 600 may be sized such thatwhen they are inserted into interface 870 they are, alternatively,already in compression, already in extended states, or in neutralstates. As shown in FIG. 38, expansion joint 700 is mechanicallyattached on both ends to header block 840 and to I-beam 850. Similarly,expansion joint 600 is attached to header block 840 and I-beam 850 byattachment through the first and second ends. Installing expansion joint600 or expansion joint 700 across interface 870 allows for independentlateral (compressive) movement between CMU concrete block 820 and I-beam850. Any such lateral movement will either compress or extend thecompressible sections of expansion joints 700 and 600. Despite thislateral movement, expansion joints 600 and 700 preferably maintain thefire-seal partition across interface 870 because each joint ismechanically fastened on each end to the I-beam 850 and the header block840. Additionally, expansion joints 600 and 700 may also allow for smallamount of drift motion (horizontal or vertical) between I-beam 850 andCMU concrete block 820. The compressible sections of both expansionjoints 600 and 700 may be designed to allow for some amount ofhorizontal and vertical drift motion between I-beam 850 and concreteblock wall 820 without the attachment flanges pulling away or detachingfrom their mounting surfaces.

Fire-Rated Angles and Straps

FIG. 39 illustrates an embodiment of a fire-rated profile or angle piece920, which is also referred to herein simply as an angle 920, alone(FIG. 39) and incorporated into a head-of-wall assembly (FIG. 41). Theangle 920 preferably is formed from a light gauge steel material by anysuitable process, such as roll forming, for example. Preferably, theangle 920 is an elongated member having a consistent or substantiallyconsistent cross-sectional shape throughout its length. In someembodiments, the angle 920 may be made from vinyl or other material. Oneor more preferred embodiments of the angle 920 are generally orsubstantially L-shaped in cross-section. In one embodiment, the angle920 may be between about 5 feet and 25 feet in length. The angle 920 canbe between about 10 and 20 feet in length. Preferably, the angle 920 isabout 10-12 feet in length to facilitate shipping and storage.Desirably, the angle 920 is sufficiently long to allow installationalong a wall with a relatively small number of pieces. However, thelength of the angle 920 should be short enough that shipping andmaterial handling is relatively convenient. Accordingly, theabove-recited lengths are presently preferred. However, other lengthsmay also be used in other situations.

Preferably, the angle 920 includes a top or upper wall portion or top orupper leg or flange 922. The upper all portion 922 is also referred toherein as a horizontal leg because it is typically oriented in ahorizontal or substantially horizontal plane when installed in ahead-of-wall assembly, as described herein. The angle 920 also includesa side wall portion 924, which is also referred to herein as a verticalleg or flange because it is typically oriented in a vertical orsubstantially vertical plane when the angle 920 is installed in ahead-of-wall assembly. The illustrated vertical leg 924 is unitarilyformed with the horizontal leg 922. That is, the horizontal leg 922 andthe vertical leg 924 are constructed from a single piece of material. Asdescribed above, typically, the single piece of material is a flat pieceof light gauge steel, which is then deformed into the shape of the angle920, such as through a roll-forming, bending (such as on a press brake)or other suitable process. Preferably, both the horizontal leg 922 andthe vertical leg 924 are substantially planar and define an angle Atherebetween of about 90 degrees or, in some arrangements, slightly morethan 90 degrees. For example, the legs 922 and 924 may define an angleof between about 80 degrees and about 100 degrees, between about 85degrees and 97 degrees or about 95 degrees. This can assist in providinga gap at the upper end of the vertical leg 924 to accommodate a fastenerhead, as is described in greater detail below.

In one embodiment of the angle 920, the horizontal leg 922 can define awidth 926 (i.e., horizontal cross-sectional dimension) of about ½ inchor less, ¾ inch or less, or 1 inch or less. Preferably, the horizontalleg 922 is about ½ inch wide. The vertical leg 924 can define a width orheight 928 (i.e., vertical cross-sectional dimension) between about ½inch and about 3 inches or more depending on amount of fire and smokeprotection desired and/or based on deflection requirements. In someembodiments, the width 928 is approximately 2½ inches. The dimensions ofthe width of the horizontal leg 922 preferably are selected such thattwo angles 920 can be employed in a head-of-wall assembly (illustratedin FIG. 41) with one angle 920 on each side of the wall. Preferably, thewidth of the horizontal leg 922 is selected such that the legs 922 ofthe two angles 920 do not overlap one another when assembled into thehead-of-wall assembly. Accordingly, if the angle 920 is configured foruse with a wall assembly that is wider than standard width, the width ofthe horizontal leg 922 can be increased to, for example, about 1½ inchesto about 3 inches, or more. The width or height of the vertical leg 924is selected such that the leg 924 fills the entire head-of-wall gap, orgap between the ceiling and upper end surfaces of the wall board, in anopen-most position of the head-of-wall joint (assuming a dynamic joint).Alternatively, the width or height of the vertical leg 924 is selectedto cover a substantial portion, such as ⅓ to ½ or more, of thecorresponding leg of the header track. Thus, the actual width or heightof the vertical leg 924 can vary from the exemplary widths or heightsdescribed herein.

In one embodiment of the angle 920, the horizontal leg 922 may include arounded bend 932. A flap 923 extends from the rounded bend 932. The flap923 can open and close with the movement of the drywall, and along withthe rounded bend 932, can help to maintain the position of the angle 920during movement of the drywall. In some embodiments, the flap 923extends at an angle from the rounded bend 932 such that the flap 923 hasa vertical height 929 of approximately ½ inch. In some embodiments, afire retardant material 933 (such as intumescent paint or tape) may beapplied to the backside or interior-facing portion of the flap 923 (thatis, the side of the flap 923 facing the drywall) to provide additionalfire protection within a deflection gap or the space above the drywallin a dynamic head of wall assembly.

In one embodiment of the angle 920, the vertical leg 924 may include anangled or kickout portion 934 that is bent outwardly (that is, in theopposite direction from the horizontal leg 922). The angled portion 934may be approximately ⅛ inch long starting approximately ½ inch from thebottom of the vertical leg 924. The purpose of this bend is to providean attachment flange that will allow the 2½ inch vertical leg 924 toalign tight against a header track without being obstructed by a framingscrew that passes through the center of a slotted header track into theframing stud. The remainder portion 936 of the vertical leg 924 extendsdownward generally parallel to the upper portion of the vertical leg924. In some embodiments, the portion 936 has a width 927 ofapproximately ½ inch. At least a portion of the vertical leg 924 may becovered or coated with a fire retardant material 931 or havefactory-applied intumescent material or tape installed over a portion ofthe leg 924. In some embodiments, an optional separate piece of fireretardant material 930 such as intumescent tape may be applied over aportion of the horizontal leg 922. Although heat-resistant adhesivepreferably is used to affix the intumescent tape 930 to the angle 920,the adhesive can still fail at temperatures lower than that required tocause expansion of the intumescent tape 930. By pinching the intumescenttape 30 between the ceiling and the angle 920, the intumescent tape 930is held in place even if the adhesive fails.

Preferably, as described above, the intumescent tape or strip 930 isconstructed with a material that expands in response to elevated heat orfire to create a fire-blocking char. One suitable material is marketedas BlazeSeal™ from Rectorseal of Houston, Tex. Other suitableintumescent materials are available from 3M Corporation, HiltiCorporation, Specified Technologies, Inc., or Grace ConstructionProducts. The intumescent material expands to many times (e.g., up to 35times or more) its original size when exposed to sufficient heat (e.g.,350 degrees Fahrenheit). Thus, intumescent materials are commonly usedas a fire block because the expanding material tends to fill gaps. Onceexpanded, the intumescent material is resistant to smoke, heat and fireand inhibits fire from passing through the head-of-wall joint or otherwall joint. Thus, intumescent materials are preferred for manyapplications. However, other fire retardant materials can also be used.Therefore, the term intumescent strip is used for convenience in thepresent specification and that the term is to be interpreted to coverother expandable or non-expandable fire-resistant materials as well,such as intumescent paints (e.g., spray-on), fiberglass wool (preferablywith a binder, such as cured urea-phenolic resin) or fire-rated dry mixproducts, unless otherwise indicated. The intumescent strip can have anysuitable thickness that provides a sufficient volume of intumescentmaterial to create an effective fire block for the particularapplication, while having small enough dimensions to be accommodated ina wall assembly. That is, preferably, the intumescent material strips donot cause unsightly protrusions or humps in the wall from excessivebuild-up of material. In one arrangement, the thickness of theintumescent strip 930 is between about 1/16 (0.0625) inches and ⅛(0.125) inches, or between about 0.065 inches and 0.090 inches. Onepreferred thickness is about 0.075 inches.

FIG. 40 illustrates another embodiment of an angle 1020. Preferably, theangle 1020 includes a top or upper wall portion or top or upper leg orflange 1022. The upper wall portion 1022 is also referred to herein as ahorizontal leg because it is typically oriented in a horizontal orsubstantially horizontal plane when installed in a head-of-wallassembly, as described herein. The angle 1020 also includes a side wallportion 1024, which is also referred to herein as a vertical leg orflange because it is typically oriented in a vertical or substantiallyvertical plane when the angle 1020 is installed in a head-of-wallassembly. The illustrated vertical leg 1024 is unitarily formed with thehorizontal leg 1022. That is, the horizontal leg 1022 and the verticalleg 1024 are constructed from a single piece of material. Preferably,both the horizontal leg 1022 and the vertical leg 1024 are substantiallyplanar and define an angle A therebetween of about 90 degrees or, insome arrangements, slightly more than 90 degrees. For example, the legs1022 and 1024 may define an angle of between about 80 degrees and about100 degrees, between about 85 degrees and 97 degrees or about 95degrees. This can assist in providing a gap at the upper end of thevertical leg 1024 to accommodate a fastener head, as is described ingreater detail below.

In the embodiment of the angle 1020 shown in FIG. 40, the horizontal leg1022 may include a corner 1032 that forms part of a Z-shaped bend withangled portion 1023 and portion 1025. Similar to the flap discussedabove, the Z-shaped bend is used to help maintain the position of theangle 1020 during movement of the drywall. In some embodiments, a fireretardant material 1033 (such as intumescent paint or tape) may beapplied to the backside or interior-facing portion of the angled portion1023 (that is, the side of the portion 1023 facing the drywall) toprovide additional fire protection within a deflection gap or the spaceabove the drywall in a dynamic head of wall assembly.

In one embodiment of the angle 1020, the vertical leg 1024 may includean angled portion 1034 that is bent outwardly (that is, in the oppositedirection from the horizontal leg 122). The angled portion 1034 may beapproximately ⅛ inch long starting approximately ½ inch from the bottomof the vertical leg 1024. The purpose of this bend is to provide anattachment flange that will allow the 2½ inch vertical leg 1024 to aligntight against a header track without being obstructed by a framing screwthat passes through the center of a slotted header track into theframing stud. The remainder portion 1036 of the vertical leg 1024extends downward generally parallel to the upper portion of the verticalleg 1024. In some embodiments, the portion 1036 has a width 1027 ofapproximately ½ inch. At least a portion of the vertical leg 1024 may becovered or coated with a fire retardant material 1031 or havefactory-applied intumescent material or tape installed over a portion ofthe leg 1024. In some embodiments, fire retardant material 1030 such asintumescent tape or paint, may be applied over a portion of thehorizontal leg 1022. In some embodiments, the fire retardant material1030 and 1031 may be continuous, that is, without any gaps, such thatthe fire retardant material covers at least a portion of the horizontalleg 1022 and wraps around the corner and covers at least a portion ofthe vertical leg 1024 to provide a fire retardant seal against theabutting surface.

FIG. 41 illustrates a wall assembly 140 (in particular, a fluted pandeck metal stud wall assembly) including an embodiment of the angle 120installed on each side of a slotted header track 142. The fluted pandeck 100 includes a pan 102, which defines downwardly-opening spaces,voids or flutes 104, and a layer of concrete 106 supported by the pan102. In the illustrated arrangement, the wall assembly 140 is orientedperpendicular or substantially perpendicular to the flutes 102 of thefluted pan deck 100. Fire-rated walls require fire-resistant material,such as mineral wool 110, to be installed within the voids 104 of thefluted pan deck 100 when the wall assembly 140 is running perpendicularto the flutes 104. The voids or flutes 104 of a fluted pan deck 100 varyin size but generally are about 7½ inches by 3 inches. Mineral wool 110is compressed and placed into these voids 104. A fire spray material 112(e.g., a fire-resistant elastomeric material that can be applied with asprayer) is then sprayed over the top of the mineral wool 110 to protectagainst smoke passage. The fire spray 112 will generally haveelastomeric qualities to it for flexibility and in some cases may evenhave intumescent qualities. In traditional stuff and spray assemblies,the fire spray 112 will go over the mineral wool 110 and lap over thetop edge of the wall board 150, for example, by about ½ inch. Fasteners152 secure a metal stud 146 to the slotted header track 142. Fasteners148 secure the angle 920 to the metal stud 146 through a slot of theheader track 142, preferably through the recessed flange portion 136 ofthe vertical leg 124 of the angle 920. The fasteners 148, 152 may be ½inch framing screws. Drywall is installed over the frame studs 146,lapping over the vertical leg 124 of the angle 920 and leaving adeflection gap between the edge of the drywall 150 and the underside ofthe fluted pan deck 100.

An aspect of the present invention involves the realization that, in aconventional arrangement, because the fire spray 112 extends over twodissimilar materials, i.e., the mineral wool 110 which is compressibleand wall board (e.g., drywall) 150 which is rigid, a great deal ofstress is created in the fire spray 112 covering the deflection gap asboth materials will act differently as they are cycled up and down. Themineral wool 110 is flexible and will be more forgiving as it cycles,but the drywall 150 is rigid and will pull away from the mineral wool110 and fire spray 112. Therefore, as these assemblies go through themovement cycle test of UL 2079, the fire spray tends to rip or tearalong the joint between the drywall and the mineral wool. Cracks, rips,or tears create a weak spot in the joint and it becomes very vulnerableto the air-leakage test and burn test that follow the movement cycletest according to UL 2079. However, in the arrangement illustrated inFIG. 41, it is apparent that the fire spray 112 only laps on theintumescent angle 120. The wall board (e.g., drywall) 150 is able tocycle unencumbered against intumescent angle 120 without stress cracksto the fire rated deflection joint. Such an arrangement is capable ofproviding a Class III Seismic movement joint according to UL 2079.Traditional stuff and spays typically are only capable of providingClass II Wind Movement according to UL 2079 because these types ofjoints are very vulnerable to cracking or tearing. FIG. 41 illustratesthe wall in a position in which the upper edges of the wall board 150are below the fire spray 112.

FIG. 42 illustrates a wall assembly 140 similar to the wall assembly 140shown above in FIG. 41 but with a solid concrete ceiling 106. TwoZ-profile angles 1020, such as those described above with respect toFIG. 40, are installed on each side of the metal stud 146. The left sideof the wall assembly 140 shows an open deflection joint with the angle1020 in an open or uncompressed state. The right side of the wallassembly 140 shows a closed deflection joint with the angle 1020 in acompressed state and illustrates how the angle 1020 conforms to themovement of the drywall 150.

Preferably, the header track 142 is installed to the concreteslab/ceiling 106 prior to the angles 1020. As described, the angles 1020can have additional fasteners 148 installed through the header track 142and leg 124 of the angle 1020 in the spaces or bays between studs 146 tohold it in place or it can be a compression friction fit utilizinginterference features. Additional fasteners 152 may be used to securethe header track 142 to the stud 146. FIG. 42 illustrates a gap or aspace 190 between the outside leg surface of the header track 142 andthe inside surface of the vertical leg 1024 of the angle 1020 at leastat an upper end of the leg 1024 and, preferably, only at an upper end ofthe leg 1024. This gap 190 has a function and purpose as it allows thehead portion of the framing screw 148 to fit between the outside legsurface of the header track 142 and the inside surface of the verticalleg 1024 of the angle 1020, as shown in FIG. 42. This allows the bottomportion of the angle leg 1024 to push up tight against the outside legsurface of the header track 142 without causing damage to theintumescent material 1031 or angle 1020 during the cycling of the wallassembly or the movement cycle test of the UL 2079 fire-rated wall jointtesting protocol.

Another embodiment of a deflection angle 1120 is shown in FIG. 43. Inthis embodiment, the angle 1120 includes a horizontal leg 1122integrally formed with a vertical leg 1124 as discussed above withrespect to the angles 920, 1020. A fire retardant material, such asintumescent tape 1130, extends vertically upward past the corner of theangle 1120 to assist with sealing the angle 1120 against unevensurfaces. The short horizontal leg 1124 can be bent at 85-95 degrees andtilt slightly downward away from or upward towards the overheadstructure to further assist in sealing the angle 1120 against unevensurfaces. Similar to the angles 920, 1020 discussed above, the angle1120 may include a ⅛ inch bend 1134 to allow the angle 1120 to havetight alignment against the header track and stud without interferingwith the framing screw or fastener to passes through the slot of theslotted header track.

FIGS. 44A-C illustrate three options for the location of the fireretardant material, such as an intumescent paint or tape, on an angle1220. As shown in FIG. 44A, the intumescent strip or tape 1230 can wraparound the corner joining the horizontal leg 1222 and the vertical leg1224. In this configuration, the angle 1220 can provide fire protectionalong two different surfaces abutting each of the legs 1222, 1224. FIG.44B illustrates another configuration in which a fire retardantmaterial, such as intumescent paint, is applied along the headertrack-facing portion of the vertical leg 1224 above the kick out portionand also along the horizontal leg 1222. In FIG. 44C, the angle 1220 hasone strip 1230 of intumescent material applied to the horizontal leg1222 near the corner and a second strip 1231 of intumescent materialapplied approximately halfway along the length of the longer, verticalleg 1224.

FIGS. 45A and B illustrate two embodiments of a strap 1320 that includesa hem 1338 extending from the lower end of the vertical leg 1324. Inthis embodiment, the strap 1320 is not bent to create an angle, as shownin FIGS. 39-44. In FIG. 45A, the intumescent material 1330 extendsbeyond the end of the vertical leg 1324 of the strap 1320. In FIG. 45B,the strap 1320 is formed from a single sheet of light gauge metal thatis bent to form a two ply vertical leg 1324. In some embodiments, fireretardant material 1331 may be applied between the layers of steelforming the vertical leg 1324. In some embodiments, an intumescent strip1330 is applied to the upper end of the vertical leg 1324 such that thestrip 1330 extends above, or beyond the edge of, the vertical leg 1324.The strip 1330 is preferably compressible to assist with sealing thestrap 1324 against an uneven surface. Similar to the embodiments shownin FIGS. 39-44, the strap 1324 includes a bent or kick out portion toallow room for framing screws that pass through the slot in the headertrack. In some embodiments, a hem 1338 provides additional structuralstability for the strap 1320 since the strap 1320 lacks a horizontal legto facilitate attachment to a wall assembly surface.

FIG. 46 illustrates a profile view of another embodiment of a strap 1420similar to the angles and straps discussed above with reference to FIGS.39-45. Instead of a planar horizontal leg, the strap 1420 includes acurved portion 1422. The strap 1420 can be bent to form a curved hookthat can mate with a piece of snap-in trim, such as trim piece 15. Thetrim piece 15 can be snapped into place with the strap 1420 afterdrywall has been installed. Other suitable interconnecting orinterlocking arrangements could also be used. The snap-in cover trim 15can made from any type of metal or other suitable material. Furthermore,although illustrated as a strap, an angle piece could be similarlyconfigured to interact or engage with a snap-in trim piece. Similar tothe embodiments shown in FIGS. 45A and 45B, the strap 1420 includes afire-retardant material such as an intumescent strip 630 that extendsbeyond the end of the strap 1420 above the curved portion 1422.

FIG. 47 illustrates a sectional view of a wall assembly and head-of-walljoint 1240 incorporating the strap 1420 illustrated in FIG. 46. The wallassembly 1240 is similar to that shown in and described with referenceto FIG. 42 in which a metal stud framed wall is attached to a solidconcrete deck. Accordingly, the same reference numbers are used todescribe the same or corresponding components. The strap 1420 isinstalled, preferably after the header track 142, such that theintumescent strip 1430 contacts the solid concrete deck 106 to form afire-block. The trim piece 15 can be snapped into place afterinstallation of the drywall 150. Preferably, the snap-in trim piece 15does not impede the unencumbered movement of the head-of-wall joint. Thetrim piece 15 preferably extends downwardly past the edge of the drywallsuch that the open deflection joint is not exposed even if in a fullyopen position.

FIG. 48 illustrates a front view of an angle piece 720 similar to theangle pieces shown in FIGS. 39-45 and discussed above. The angle 720 ispreferably formed from light gauge steel with cuts or slits made on thelong edge of the angle 720 to create bendable tabs 750. In oneembodiment, the height or width 752 of the angle 720 is approximately 2½inches. The height or width 754 of each tab 750 is approximately ¾ inch.Each tab 750 has a width 756 of approximately ½ inch and each tab 750 isapproximately ¾ inch on center. The plurality of bendable tabs allowsthe angle 720 to be bent during installation to secure or lock in thestud, as discussed below. FIG. 49 illustrates the angle 720 in profileview to illustrate one possible location of an intumescent strip 730.Similar to the angle profiles discussed above, angle 720 includes ahorizontal leg 722 and a vertical leg 724 that are preferably formedfrom a single sheet of light gauge steel that is bent to form the legs722, 724. As shown, the intumescent strip 730 may be located on aninterior-facing surface of the vertical leg 724 just below the cornerbetween the vertical leg 724 and the horizontal leg 722.

FIG. 50 illustrates a wall assembly 340 that incorporates the angle 720shown in FIGS. 48 and 49. The wall assembly 340 is similar to that shownin and described with reference to FIGS. 42 and 47 in which a metal studframed wall is attached to a solid concrete deck. Accordingly, the samereference numbers are used to describe the same or correspondingcomponents. In FIG. 50, the tabs 750 of each angle 720 are pushed in tolock in or secure the metal stud 146 relative to the header track suchthat, in some configurations, the use of a fastener is not necessary.

FIG. 51 is an elevation view of the wall assembly 340 of FIG. 42. Theangle 720 with tabs 750 is installed over the header track 142. Thestuds 146 are nested into the header track 142 and the tabs 750 of theangle 720 are pushed in on either side of the stud 146 to prevent thestud 146 from moving side to side. While FIGS. 48-51 illustrate oneembodiment of the angle 720, any of the tab and slit concepts discussedabove may be used with any of the angles shown in FIGS. 39-46.

The above-described arrangements can also be utilized at a gap at thebottom of the wall assembly and at a gap at the side of the wallassembly. Preferably, each such assembly is similar to the head-of-wallassemblies described above. In particular, preferably, each suchassembly creates a fire-resistant structure at the respective wall gap.

The described assemblies provide convenient and adaptable fire blockstructures for a variety of linear wall gap applications, which in atleast some embodiments permit the creation of a fire rated jointaccording to UL 2079. In some arrangements, the separate angles includefire-retardant materials (e.g., intumescent material strips) secured(e.g., adhesively attached or bonded) to appropriate locations on theangles and can be used with a variety of headers, footers (bottom tracksor sill plates) and studs to create a customizable assembly. Thus, oneparticular type of angle can be combined with multiple sizes or types ofbase tracks, headers, sill plates or studs to result a large number ofpossible combinations. The angles can be configured for use withcommonly-available tracks, headers, sill plates or studs, in addition tocustomized tracks, headers, sill plates or studs specifically designedfor use with the angles. Thus, the advantages of the described systemscan be applied to existing wall assemblies. Therefore, the angles can bestocked in bulk and used as needed with an appropriate framingcomponent.

Non-Metal Fire-Rated Component

In some configurations, any of the above described fire-rated angles,straps and joints may be formed from a non-metal material. Non-metalmaterials may include plastics such as, but are not limited to, vinyl,polyvinyl chloride (PVC), polyethylene or the like. Preferably, thenon-metal material has a melting temperature that is higher than theinitiation temperature of intumescent material (e.g., greater than 350degrees Fahrenheit) such that the intumescent material expands prior tothe melting of the non-metal material in response to elevated heat orfire. Preferably, the non-metal material has a melting temperature of atleast 400 degrees Fahrenheit. In addition, preferably the non-metalmaterial is fire-resistant and/or self-extinguishing such thatcombustion ceases once a flame source is removed.

In contrast to fire-rated components (e.g., angles, straps, joints,etc.) that are formed from light gauge steel, non-metal materials maydeform gradually when under the pressure of the expanding intumescentmaterial. That is, non-metal materials will deform (but not melt) at alower temperature than light gauge steel which allows greaterdeformation than light gauge steel but at a rate of deformation that isstill slower than the expansion of the intumescent material.Accordingly, the gradual deformation of the non-metal material providessupport for the expanding intumescent material such that the expansionof the intumescent material may be controlled and directed to fill thegaps between, for example, the head-of-wall joint or other wall jointsthereby providing a seal along the joint at which the angle isinstalled. In some configurations, a non-metal angle or strap may beconfigured such that deformed portions of the non-metal angle or straprestrict expansion of the intumescent material in certain directionswhile allowing expansion in other directions such that the intumescentmaterial swells and fills a wall gap instead of merely spilling out ofthe wall gap. That is, the deformed portions of the non-metal angle orstrap may contain the expanding intumescent material within the wall gapsuch that the intumescent material expands within the wall gap. Putanother way, the non-metal angle or strap retains a sufficient amount ofrigidity while it deforms such that the expanding intumescent materialis directed in a desired direction or constrained within a gap to besealed by the intumescent material.

For example, in an exemplary embodiment, the fire-rated angle 200 of,for example, FIG. 18 may be formed from a non-metal material instead ofa light gauge steel. In some configurations, the fire-rated angle 200 isformed from a non-metal material having a melting temperature that ishigher than the initiation temperature of intumescent strip 300. FIG.52A illustrates a wall assembly 1300 within which the non-metal angle200 has a horizontal leg 220 positioned between the header track 42 andceiling element 104. The non-metal angle 200 has a vertical leg 240positioned between the header track 42 and the wall board 50. Anintumescent strip 300 is positioned on an interior surface of thevertical leg 240 of the non-metal angle 200. The intumescent strip 300is positioned between the vertical leg 240 and a vertical flange of theheader track 42. A gap 1302 is defined by a top surface of the wallboard 50, a bottom surface of the ceiling element 104 and a surface ofthe vertical leg 240 that is opposite the intumescent strip 300.

FIG. 52B illustrates the non-metal angle 200 after the wall assembly1300 has been exposed to a temperature greater than the initiationtemperature of the intumescent strip 300. As shown, the non-metal angle200 is deformed by the expansion of the intumescent strip 300. Morespecifically, the intumescent strip 300 has expanded between the headertrack 42 and the non-metal angle 200 such that a portion of thenon-metal angle 200 is deformed away from the header track 42 andthrough the gap 1302. In some configurations, at least an unconstrainedportion of the vertical leg 240 (i.e., unconstrained by the wall board50) deforms in response to elevated temperature that approaches amelting point of the material of the non-metal angle 200 and/or theinitiation temperature of the intumescent strip 300. In someconfigurations, the deformed portion of the non-metal angle 200 caninclude portions or entireties of one or both of the unconstrainedportion of the vertical leg 240 and the horizontal leg 220. As shown, insome configurations, a deformed portion of the non-metal angle 200 canbe bent over the top surface of the wall board 50 and can extend upwardtowards the ceiling element 104 to form a partially or fully enclosedcavity 1304 within which the intumescent material 300 is contained anddirected to expand upwardly toward the ceiling element 104. That is, inat least some configurations, the non-metal angle 200 deforms and mayeven split, separate or rupture in one or more locations; however, thenon-metal angle 200 retains sufficient structural integrity such thatthe cavity 1304 keeps the intumescent material 300 within the gap 1302.This can be accomplished by material selection, material thickness,coatings, combinations thereof or other suitable arrangements. Thecavity 1304 also provides a protective covering over the expandedintumescent material 300 which partially or fully conceals theintumescent material 300 without negatively limiting its expansion. Thecavity 1304 can also provide support to a bottom and lateral surface ofthe expanding intumescent material 300 such that it may expand upwardand seal against the ceiling element 104. The expanded intumescentmaterial 300 also protects the non-metal angle 200 from heat transmittedfrom the header track 42 such that the non-metal material of the angle200 does not melt.

In some configurations, the non-metal angle 200 deforms outwardlythrough the gap 1302 a lateral distance of at least 1 inch away from theheader track 42. Accordingly, providing a wider cavity 1304 within whichthe intumescent material 300 may expand may provide a wider region ofexpanded intumescent to provide greater heat protection, thereby,preventing or inhibiting heat from passing through the header track 42and to the wall board 50, or vice versa.

It should be understood to one of ordinary skill in the art that theintumescent strip 300 is not limited to a position on the header-facingsurface of the vertical leg 240. In other words, the angle 200 may haveone or multiple intumescent strips positioned along any portion of theangle 200. Other suitable fire-retardant materials (expanding ornon-expanding) may also be used, such as those described herein. Inaddition, the combination of intumescent material and non-metal materialis not limited to only angles and depicted wall assemblies. Straps andother fire-rated wall assembly components may be formed from non-metalmaterial such that the direction of the expanding intumescent materialmay be controlled.

FIGS. 53 and 54 illustrate an alternative configuration of a fire-ratedcomponent (e.g., angles, straps, joints, etc.) for creating a sealagainst uneven or wavy concrete surfaces. Similar to previouslydescribed fire-rated components, the fire-rated angle 200 in FIGS. 53and 54 may be formed from a metal or a non-metal material. However, incontrast, the fire-rated angle 200 includes a compressible gasket 322positioned over the corner 320 of the angle 200 on an outwardly-facingside of the angle 200 along the length of the angle 200. That is, thegasket 322 is positioned on a side of the angle 200 that faces away fromthe header track 42. The gasket 322 has a first end attached to thehorizontal flange 220 and a second end attached to the vertical flange250 and, in at least some configurations, is not connected to the angle200 in between the ends such that an interior space is formed. The spacecan be empty or filled with a filler material (e.g., foam).

As shown in FIG. 54, when the angle 200 is assembled as a component of awall assembly 1400, the gasket 322 is compressed between the concreteslab/ceiling 44 and the horizontal leg 220. The gasket 322 provides anair seal to protect against smoke, fire and sound passing through thegap between the angle 200 and the concrete slab/ceiling 44. That is, thegasket functions to seal a gap between the angle 200 and the ceiling 44,which can be caused by imperfections or irregularities of the ceiling 44surface. The ceiling 44 surface may not be completely flat or planar, ascan be the case with poured concrete decks, for example. In someconfigurations, the intumescent strip 300 on the vertical leg 240 of theangle 200 may also be compressed between the vertical flange of theheader track 42 and the angle 200 such that the gap between the headertrack 42 and the ceiling 44 is sealed.

As shown, the gasket 322 is illustrated as being circular incross-section. However, the gasket 322 is not limited to any particularcross-sectional shape and may include curved, flat, and polygonal shapesor any combination thereof. The gasket 322 may be formed from acompressible material such as rubber, foam, plastic, etc. In someconfigurations, the gasket 322 is formed from a fire-resistantcompressible material such as Denver Foam®. The gasket 322 may be formedby molding the gasket directly onto the angle 200. Alternatively, thegasket 322 may be attached to the angle 200 by an adhesive or mechanicalfastener. In addition, the gasket 322 is illustrated as having a tubularshape with a hollow center. However, in some configurations, the gasket322 may have a solid center while maintaining elasticity andcompressibility.

In some configurations, the gasket 322 may be attached to at least oneof the horizontal flange 220 or the vertical flange 240. For example, insome configurations, the gasket 322 may be attached to only thehorizontal flange 220. Similarly, one or more gaskets 322 may bepositioned multiple portions of the angle 200 such that a seal is formedbetween the angle 200 and the concrete ceiling 44.

It should be understood to one of ordinary skill in the art that thegasket 322 may be utilized with a variety of wall components such as,but not limited to, straps, joint members, etc. That is, the gasket 322may be attached to and positioned on wall components such that thegasket 322 provides a seal between the wall component and an adjacentmember.

Although this invention has been disclosed in the context of certainpreferred embodiments and examples, it will be understood by thoseskilled in the art that the present invention extends beyond thespecifically disclosed embodiments to other alternative embodimentsand/or uses of the invention and obvious modifications and equivalentsthereof. In particular, while the present angle piece and assemblieshave been described in the context of particularly preferredembodiments, the skilled artisan will appreciate, in view of the presentdisclosure, that certain advantages, features and aspects of the anglepiece and assemblies may be realized in a variety of other applications,many of which have been noted above. Additionally, it is contemplatedthat various aspects and features of the invention described can bepracticed separately, combined together, or substituted for one another,and that a variety of combination and subcombinations of the featuresand aspects can be made and still fall within the scope of theinvention. For example, the specific locations of the intumescent stripscan be utilized with the variety of different embodiments of the anglepieces disclosed herein in addition to those embodiments specificallyillustrated. Thus, it is intended that the scope of the presentinvention herein disclosed should not be limited by the particulardisclosed embodiments described above, but should be determined only bya fair reading of the claims.

1.-35. (canceled)
 36. A fire-rated assembly for a linear wall gap,comprising: a track that has a web, a first flange and a second flange,wherein the web is substantially planar and has a first side edge and asecond side edge, the first flange and the second flange extend in thesame direction from the first and second side edges, respectively,wherein each of the first and second flanges is substantially planarsuch that the track defines a substantially U-shaped cross section; anangle piece comprising a first flange, a second flange oriented at afirst angle relative to the first flange, the first flange and thesecond flange being connected to one another along an edge therebydefining a corner, the first and second flanges being formed from anon-metal material; and a heat-expandable intumescent strip attached toone of the first and second flanges of the angle piece, theheat-expandable intumescent strip having an activation temperature thatis lower than a melting temperature of the non-metal material, wherein,in use, the first flange of the angle is positioned adjacent to anoverhead structure with the second flange of the angle being positionedadjacent one of the first or second flanges of the track, wherein theangle piece is configured to deform and contain expanding intumescentmaterial of the heat-expandable intumescent strip when the angle pieceand the heat-expandable intumescent strip are exposed to temperaturesgreater than the activation temperature.
 37. The fire-rated assembly ofclaim 36, wherein the non-metal material is comprised of polyvinylchloride (PVC).
 38. A fire-rated wall joint product, comprising: anangle piece comprising a first flange, a second flange oriented at afirst angle relative to the first flange, the first flange and thesecond flange being connected to one another along an edge therebydefining a corner, the first and second flanges being formed from anon-metal material; and a heat-expandable intumescent strip attached toone of the first and second flanges, the heat-expandable intumescentstrip having an activation temperature that is lower than a meltingtemperature of the non-metal material, wherein the angle piece isconfigured to deform and contain expanding intumescent material of theheat-expandable intumescent strip when the angle piece and theheat-expandable intumescent strip are exposed to temperatures greaterthan the activation temperature.
 39. The fire-rated wall joint productof claim 38, wherein the non-metal material is comprised of polyvinylchloride (PVC).
 40. A fire-rated wall joint product, comprising: a bodyportion comprising a first end and a second end, the body portion beingformed from a non-metal material; and a heat-expandable intumescentstrip attached to the body portion between the first and second ends,the heat-expandable intumescent strip having an activation temperaturethat is lower than a melting temperature of the non-metal material,wherein the non-metal material is configured to deform and containexpanding intumescent material of the heat-expandable intumescent stripwhen the body portion and heat-expandable intumescent strip are exposedto temperatures greater than the activation temperature.
 41. Thefire-rated wall joint product of claim 40, wherein the non-metalmaterial is comprised of polyvinyl chloride (PVC).
 42. A fire-ratedassembly for a linear wall gap, comprising: a track that has a web, afirst flange and a second flange, wherein the web is substantiallyplanar and has a first side edge and a second side edge, the firstflange and the second flange extend in the same direction from the firstand second side edges, respectively, wherein each of the first andsecond flanges is substantially planar such that the track defines asubstantially U-shaped cross section; an angle piece comprising a firstflange, a second flange oriented at a first angle relative to the firstflange, the first flange and the second flange being connected to oneanother along an edge thereby defining a corner; and a gasket attachedto the angle piece, the gasket comprising a compressible material,wherein, in use, the first flange of the angle is positioned adjacent toan overhead structure such that the gasket contacts the overheadstructure to form a seal between the first flange and the overheadstructure.
 43. The fire-rated assembly of claim 42, wherein the gasketis attached to the first flange of the angle.
 44. The fire-ratedassembly of claim 42, wherein a first end of the gasket is attached tothe first flange and a second end of the gasket is attached to thesecond flange such that the gasket is positioned over the corner of theangle piece.
 45. The fire-rated assembly of claim 42, further comprisinga heat-expandable intumescent strip attached to one of the first andsecond flanges of the angle piece.
 46. A fire-rated wall joint product,comprising: an angle piece comprising a first flange, a second flangeoriented at a first angle relative to the first flange, the first flangeand the second flange being connected to one another along an edgethereby defining a corner; and a gasket attached to the angle piece, thegasket comprising a compressible material.
 47. The fire-rated wall jointproduct of claim 46, wherein the gasket is attached to the first flangeof the angle.
 48. The fire-rated wall joint product of claim 46, whereina first end of the gasket is attached to the first flange and a secondend of the gasket is attached to the second flange such that the gasketis positioned over the corner of the angle piece.